It’s the Fourth of July, and you have everyone over to witness your pitmaster skills. You’ve planned a delicious backyard BBQ and splurged on the perfect cuts for this occasion.

Then your grill malfunctions.

This situation isn’t uncommon, especially in older pellet grills. The more you grill, the weaker your smoker gets — a natural consequence of wear and tear. But before you decide to throw your pellet grill out for a new one, you may be able to repair it yourself with one of these smoker repair hacks.

For Repairing Leaks: How to Seal a Smoker

Even though this issue is less common in newer, more advanced pellet grills, it can still happen — especially if you’ve been using your smoker for a while. Leaks can occur at any time, and they can be hard to detect. It’s important that you find any leaks in your smoker immediately, though, so you don’t continue to lose heat when you grill.

Fortunately, most minor leaks can be fixed with a high-temperature caulk or sealant. High-temperature caulks are typically silicone-based substances that can adhere to most surfaces, including metal, ceramic and wood. In most lid leak situations, all you need is a thin lining around the edge of the lid. Most high-temp sealants can withstand temperatures of up to 2,000 degrees Fahrenheit, if not more. That means if they are applied correctly, they can help extend your pellet grill’s lifespan significantly.

High-temperature caulks are also great options for fixing minor cracks and holes in your smoker. All you need to do is apply a thin layer of the sealant to the crack or puncture. Wait for it to dry, and then gently cut or sand away any unsightly excess cement.

Other Common BBQ Smoker Problems and Fixes

Leaks may be the culprit of most pellet grill problems, but many other smoker issues can plague your backyard barbecues. Here are a few possible scenarios pellet grill users may encounter.

1. Electrical Cord Issues

Sometimes, you’ll find that the electrical cord that came with your grill isn’t quite long enough to reach your outdoor power outlet. In such cases, it makes sense to grab that extension cord you saw lying around, but be careful with this. Most household extension cords lack the capacity to safely power grills like our wood pellet grills. Your best bet is to contact an electrician to figure out what type of extension cord you can safely use with your smoker.

2. Missing/Broken Parts

Smoker parts like knobs, handles and others can break or go missing over time. If this happens, always check with your pellet grill manufacturer for the necessary part availability. Make sure you have a user manual on hand, too, so you can correctly install your parts when they arrive.

3. Error Codes

Especially if your pellet grill has Wi-Fi capabilities, you may run into error codes every now and then. Since error codes correspond to specific problems detected in your smoker, you need to verse yourself in their meanings. If you don’t have your user manual on hand, your manufacturer’s website should have that information.

If you’re having trouble with your pellet grill, don’t go into panic mode. With a few tweaks or part replacements, it’s possible to get your smoker working like new. And, of course, if you have any trouble, we’re here to help!

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