Smoke issues with Bronco

[Reds Fan 5]

After a long run of successful cooks on my OKJ Bronco I am fighting smoke issues. I am using the same set up I’ve always used: KBB, multiple fire starters in the coals, Weber wood chunks.

Grease trap is clean. I don’t deep clean the smoker, just burn offs.

Typically it takes about an hour to get clean smoke at desired temp. The last few cooks it’s taken about an hour and 20 mins. It starts pumping “dirty” smoke in the middle of the cook and then runs clean again. There is no wood smoke aroma and the food either tastes over smoked or a bit like campfire rather than apple/oak/pecan, etc. I thought my charcoal might be damp so used a fresh bag. Same issues. I bought a new bag of wood. Still didn’t fix the issue. Family says the food tastes good and wonders if it’s my nose/palate.

If I had struggled with the Bronco from the beginning I’d get it. But losing my touch after a long run of good cooks is perplexing.

Welcome any troubleshooting ideas my fellow Bronco/drum users might have.

[tstalafuse]

Sounds like an air flow problem to me. Have you checked to make sure something hasn't taken up residence in the air intake? Maybe the residual build up has reached a tipping point, and it is time for the deep cleaning with a heavy duty degreaser and power washer.

[Reds Fan 5]

I am sure there isn’t any nesting or wildlife related blockage; however, it is possible there is other build up.

[WI Bubba]

I agree. Something has changed with the air flow.

[Alan Brice]

Trade it in for a PBC, PBC, PBC!!!

[Uncle Bob]

Alan, Alan, Alan...........I get you're poking fun but do we really want to start a sniping campaign with all the quirk dealing PBC people post? If so, there could be a lot more incoming on the PBC than the Bronco.

[Alan Brice]

Geez uh Reds Fan 5 I do not have a Bronco so I really have nothing of value for you at this time. ,,,

[klflowers]

Alan Brice ignore Uncle Bob. He is just an ornery old cuss. Reds Fan 5 trade it for a WSM

[dpearce]

Has it been as humid where you're located as it has been for us here in central Ohio? I'd imagine enough humidity and air density could technically change your cooks. Just guessing here, but something to think about.

[Reds Fan 5]

I live in suburban Chicago. We’ve had a very humid summer. That’s why I wondered if the charcoal or the wood were bad.

[dpearce]

Reds Fan 5 Yeah, we're sweltering here too. My KBB's and wood seems ok, but I noticed when the temp and humidity were up, it takes a little longer for the smoke to burn clean. The times you're mentioning seem like a bit much though, and not sure what to think about your cook "burning dirty" after it's already been going awhile. Hopefully a resident expert can help out here.

[Ace]

Wonder if you might try cracking the firebox door a bit and see if that helps get to a clean smoke and temp level quicker. Also, if it burns dirty in the middle of the cook, try cracking the door. If that helps, it would be good to do a deep clean on the air inlet system. Let us know how it works out for you.

[Uncle Bob]

The Bronco is a drum smoker, no door (at least on the first gen), only intake and exhaust tubes.

[Ace]

Uncle Bob Interesting. I've not tried a drum smoker before. Looks like they could be fun however...

[Uncle Bob]

As said above, definitely a fire temp problem. Either fuel or air isn't doing it's part as normal.

[J-Melt]

I did a couple of chickens on Sunday in my OJB here in south side Chicago. I was a little confused about how dirty it was running as it never really cleared up. I was using combination of Kirkland and Cowboy briquettes. Maybe it does have something to do with the humidity???

[Reds Fan 5]

The last problematic cook we had a 100 degree heat index. When I put the probe in the grate clip it read 102 before the fire had started. I move our patio umbrella to keep the cooker in the shade. That helped a bit but the cooker was definitely running hot. As you will see in another comment I’m posting I think I solved the problem

[klflowers]

I have a Bronco and just did a pork butt in it here in Chattanooga. Talk about humid! Anyway I used KBB and some fruita wood cherry chunks. Ran for ~12 hours. No problems with smoke quality. Like these guys said, sounds like air flow. Or maybe a bad bag of KBB.

[Jessterr]

A few folks have mentioned humidity, I’m wondering if just the high ambient heat might be a culprit as well. What were your target smoker temperature(s), and how do you describe clean and dirty smoke? Just guessing here, but a black smoker in direct summer sun on a hot day might easily get up to an internal temperature of 120-140F by itself? If so, it wouldn’t take too much heat from the charcoal to get it up to 225-250F, so maybe the fire is being choked a bit trying to maintain a relatively low temperature? If what you describe as dirty smoke in the middle of the cook is really just heavier white smoke, maybe it’s really just a new wood chunk lighting off. I’m just guessing here, obviously, but if the family says the food tastes good they’re probably right. You may be suffering from the known phenomenon of the pitmaster not enjoying the food as much right after the cook, due to having been exposed to the smoke all day, it is a real thing. Wondering if, in this summer heat, starting with fewer fire starters (maybe just one?) within a tighter area in the charcoal bed, i.e, a smaller fire, might help address some of the issues by requiring higher air flow in order to maintain the same target temperatures?

[J-Melt]

Mine was goal of anything above 325, so I had the damper 50-100% open. I was also wondering if a deep clean might be a good idea.

[Jessterr]

Yeah, I was probably off base then. Would be interested in hearing how things go after the deep clean!

[DTro]

The heat and humidity mentioned above, plus drippings from the cook hitting the coals in the middle of your cook.

[jecucolo]

Have you tried using a different brand of charcoal? Maybe try some B & B briquettes.

[Reds Fan 5]

Thanks to everyone for your responses. There was a little build up at the bottom of the intake pipe but not much. The comments about heat/humidity caught my attention. I was also fighting high temps even in temperate weather. These were 4-8 hour cooks, not 10-15 hour cooks, so I was lighting 2 or 3 starters in the charcoal with wood chunks near each starter.

Yesterday I smoked pork belly burnt ends. A 4-4.5 hour cook. I lit one starter. Problem solved! Great smoke flavor, great cook.

It wasn’t a perfect cook, though. My prep table is opposite the cooker so if I’m wrapping my back is to it. I removed the burnt ends to put them in a foil pan for the second half of the cook. I feel a blast of heat behind me. Turn around to see I didn’t close the lid, my 250 degree slow burn fire was a full on 420 degree bonfire. So finished the pork in the oven and got a good burn off in the smoker.

[fzxdoc]

Yikes. That's got to hurt. You must be sleeping on your belly for a night or two.

Kathryn

[Reds Fan 5]

Fortunately it didn’t burn me. The diffuser plate was in place so that helped.