I'll be drilling my kettle to add a PartyQ and a probe port. From reading here and looking around with google, I'll start with a pilot hole and expand with a step bit. I did have a few questions for wisdom of the pit:
Drill from the inside out, or the reverse, to minimize cosmetic damage?
Use BBQ paint to paint the exposed metal? Sound like that would be overkill, but thought it worth checking.
Is the WSM Grommet good in the kettle? Can it handle the higher heats used when cooking non low and slow foods, say a kettle full of burgers?
Center punch the spot you want to drill to keep drill from walking. Drill in any direction you can easily. Use a larger diameter drill (or the next size up with a step drill) carefully to remove any burrs around holes. Skip the paint and grommet. Soot will protect the metal after a few cooks. I drilled two holes and have no problem holding low temps.
If you are using the Weber adapter it’s nice and tight you don’t need much else. Hole should be above the ash sweepers but below the charcoal grate. I put the fan opposite where the Slow-N-Sear sits. Foil on the grate under the meat to make all the air go over to the coal basket, upper vent over the meat to make the hot air and smoke travel across the meat.
1: Typically you get material blow out on the exit side of the hole, unless you can clamp a wood block or similar; so I, personally, would drill from the outside.
2: I would absolutely treat the exposed metal.
3: I have no experience with that, so can not help there.
I’ve done my kettle for a fan port (Pit Viper) and a WSM grommet. As said, drill a pilot hole from the outside in, tape the areas with blue painters tape, run your step drill to desired diameter.
The Pit Viper hole is 1†for fan port and 1 1/4†for the WSM grommet. Fan is opposite where SNS sits but be aware as not to block the sweep blades. Grommet should sit about 1†above the cooking grate.
After cutting you will need a circular file to clean up the rough edges. Then re-tape and paint the bare metal with a good BBQ heat resistant paint (Rustoleum is good). Finally install your port and grommet. Grommet takes a little coaxing, so be patient.
I used a small drill bit, then a step bit to drill the holes. One for the fan and one for the probes. If you get the hole the right size, the adapter will fit. I drilled from the outside, but I don't think it would have made any difference.
I did not paint the edges of the holes, and have had no problem. If you decide to add a hole for the probes, I suggest using a close nipple. Get a cap for when you don't need probes.
I was thinking more along the lines of protecting the newly bare metal, hopefully just the edge. If the soot (and maybe some good old pork fat) will do it... why add more chemicals to the kettle.
I saw that video and it was what made me think about what direction to drill. I'm used to wood where blowout on the exit is more common (I guess) so him drilling from the inside...
I just did the PartyQ hole. From the inside I used a punch and then drilled the pilot hole. Still on the inside I used the step up to 3/4â€. It was just easier to place it right and get a comfortable angle from the inside. For the last 1/8â€, up to the final 7/8â€, I did that from the outside to leave a cleaner hole there, and it came out nice and clean. I coated it in some oil, and figure when I light up the grill it will get baked on like I’m seasoning a carbon steel pan.
I’m still evaluating how I want the hole for the probes - the Weber grommet, a nipple, or just a hole.
Last edited by cftarnas; July 26, 2018, 09:42 PM.
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