Weber Kettle Temp Probe Hole Installation

[Anton32828]

I thought I'd post the method I used to run thermometer cables through my Weber grill. There seem to be three popular methods: run the wires under the lid, or cut a notch in the kettle rim, or install the WSM big silicone grommet. The "under the lid" method crimps the wires and leaks smoke. The WSM grommet requires a bigger hole than I wanted to drill. And the "notch" method, while effective, seemed a bit radical. My solution was to use a threaded rivet, or "rivnut," to get my cables and probes into my grill.


These pictures didn't upload in the order I thought they would. Oh well, one more thing to learn.

One picture shows my grill with the thermometer sitting on a table. Note the binder clips keeping the lid sealed against smoke and air leaks. This works really well.
The exterior picture shows the nice clean look of the grommet on the Weber. The interior picture shows the relatively small length of the riv-nut inside the grill. It doesn't really interfere with anything. The final picture shows the tools that I used. I bought the riv-nut kit and step-drill from Harbor Freight. The riv-nut kit was roughly $22, so it's an economical installation.

Procedure:
(1) Select the largest riv-nut, which in this case was 1/4 inch.
(2) Tape the inside and outside of the grill to protect the ceramic coating.
(3) Drill a small starter hole midway between the kettle rim and the grill grate.
(4) Use the step drill bit to enlarge the hole to the correct size. Go slowly and use a bit of lubricating oil on the drill bit. I was out of WD40, so I used olive oil.
(5) Install the riv-nut using the tool in the kit.
(6) In my case, the threads of the riv-nut were still too small to pass the probes through, but just barely. I used a straight drill bit to enlarge the interior of the riv-nut. It's aluminum, so it is simple to carefully remove enough interior thread to allow you to push the probes into the kettle.

This has worked very nicely during today's cook. I'm doing a pork loin tasso experiment. The color isn't what I expected, but we'll see how it tastes.

Keywords: thermometer temperature probe grommet hole

[Obi-Dan]

Looks good. I need to get to doing this. Thanks for sharing such detailed steps and pics. I know lots of people here have also used threaded lamp pipe and nuts as well.

[RonB]

Good job. You can do the same thing with a close nipple.

[Anton32828]

I had to look that up

[OSB]

I have this version off of Ebay. Drill out to 13/16 and install. I've gotten 6 probes through it.

https://www.ebay.com/itm/BBQ-Grill-Smoker-Adjustable-Thermometer-Probe-Port-Seal-Yoder-Weber-Traeger/322989810670?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m1438.l2649

[OSB]

I will keep that in mind Polarbear777. I have another kettle I use for hot direct cooks and seafood.

[Tom Ewing]

Thanks for your directions. Followed them this morning. Worked perfectly!

[TripleB]

Polarbear777 - Thanks for this tip. I want to put in a probe port on my PK360 and bought a stainless steel cable gland and silicon plugs. The plastic parts on the cable gland I won't put in due to what you stated about them melting. By the way, is there any meaning to 777 on your handle?

[Mygrane]

I did this but used a grommet made from a piece of leather. I was only concerned with losing heat from the hole. But then I hold the lid down tight with large paper clips too. Ha!
I like your idea better! Nice job

[zinfella]

I think access for temp cables into the kettle that prevents damage to them is a good idea. But, I don't have the guts to drill into my kettle myself. I'm sure that Weber is aware of the issue, and I think they will add the feature to the kettle, at some point in the future.So, my Thermoworks Pro series probes & cables go in between the kettle and lid. Admittedly, not the best solution for prolonging cable life.

Besides not having the guts to drill into my kettle, I have AMD, so my vision sucks! I don't even want to think about what a mess I might make out creating a simple access hole. I'm glad some of you guys have solved the issue for yourselves, but it looks like I'll have to rely on spare cables in case of damage. Oh well..........

[Alabama Smoke]

Try dropping the business end of the cables through the lid vent holes. I do that on an 18" Jumbo Joe all the time.

Also if you install a Lava Lock gasket made for the purpose, you will not only likely have a better seal to keep temps down, but if you get one nice and thick enough to fill the "trench" on the lid that fits down into the kettle, you will likely find that your cables can be laid across the gasket, not damage the probe wires, and still get a good air seal.

[zinfella]

@Alabama Smoke- Thanks for your response, I'm sure the Lava Lock would do a better job of protecting the cables from damage than my current metal to metal setup of the lid to the kettle.

OTOH, I'm one that believes a smoke leak is pretty much a non-issue. But my lid fits tight, no rocking, sso I can control grill temps using the top and bottom vents, with the top vent doing the fine tuning. My Performer sits in my carport with walls on 2 sides, third side blocked by car, so is not normally subject to wind, which amounts to a bonus WRT temp control. Before we moved here, the Performer was under my40' patio cover out back, but open to wind on 3 sides, and was not as temp stable as it is now.

[ken g]

I did this with my Weber a few years ago. No ill effects and works well.

[zinfella]

Okay, Ken, whats that blue stuff and red stuff? Looks like plastic, nut plastic couldn't survive kettle temps.

Give it up, son!

[ken g]

It's a high temp rated hole grommet and high temp rated silicone hole plug. Been there for years now with no ill effects. Got items from Ebay.

[zinfella]

Cool!