Hondo Deluxe

MODEL 03207245

Assembly Instructions

TM

Tools needed for assembly: Phillips screwdriver • Adjustable wrench

CAUTION

Some parts may contain sharp edges – especially as noted in manual. Wear protective gloves if necessary.

CAUTION

Read and follow all safety statements, warnings, assembly instructions and use & care directions before attempting to assemble and cook.

CAUTION

THIS UNIT IS HEAVY.

DO NOT assemble without a helper.

WARNING

CARBON MONOXIDE HAZARD

Burning charcoal inside can kill you. It gives off carbon monoxide, which has no odor. NEVER burn charcoal inside homes, vehicles or tents.

Hondo Deluxe 03207245 E / 42802128(02-12-03)

STOP!

Missing a part?

No need to go back to the store!

The store where you made your purchase does not stock parts for this item. If you need parts, whether they are missing or damaged, call the Customer Service toll free Help Line.

Call us and we will gladly ship the part you need

FREE OF CHARGE.

Call Our Help Line

ITEM

55700342

55700343

55700344

55700345

55700346

55700347

55700348

55700349

55700350

55700351

55700352

55700353

PARTS LIST

DESCRIPTION

SMOKE CHAMBER KIT

SMOKE CHAMBER LID ASSEMBLY

FIREBOX KIT

FIREBOX LID ASSEMBLY

HINGE KIT

FRONT SHELF KIT

AXLE KIT

WHEEL KIT

LEG BRACE KIT

SMOKE STACK KIT

SHORT LEG KIT

LONG LEG KIT

QTY

1

1

1

1

1

1

1

1

1

1

1

1

ITEM

55700354

55700355

55700356

55700357

42000016

42802128

45602003

40009927

40009928

40002811

46030090

44830150

DESCRIPTION

KNOCKOUT COVER KIT

DOOR LATCH KIT

LOGO PLATE KIT

BUTTERFLY DAMPER KIT

HARDWARE BAG

ASSEMBLY INSTRUCTIONS

LEG EXTENDER 2

CAST IRON COOKING GRATE, Small 1

CAST IRON COOKING GRATE, Large 1

GRATE SET (3) 1

WIRE SHELF 1

GREASE CAN HOLDER 1

QTY

1

1

1

1

1

1

BEFORE BEGINNING ASSEMBLY . . . GET A HELPER!

This unit is heavy and requires a second person for lifting and moving.

Pick a suitable location to work. Open the carton and slit the corners to open like the illustration below. This will give you a protective work surface upon which to start the assembly.

DO NOT ASSEMBLE WITHOUT A HELPER.

1

• Cart should be assembled in position shown.

• Connect leg sections together as shown.

• Make sure short legs with axle holes are on the same side.

• Affix wire shelf as shown in section AA.

• Wire shelf must be attached before leg brace assembly begins.

• Attach leg braces to each side with eight 1/4 -20 x1-3/4 screws and eight

1/4-20 flange nuts.

• Thread wheel axle through both legs on the right side as shown and attach wheel using a hitch pin for each side.

• Snap hub cap into place as shown.

• Insert leg extenders into bottom of legs opposite of wheels.

Leg

Extenders

Attach

Wheel, Hitch Pin &

Hub Cap

(Repeat for other side)

Slotted

Hole

2

Attach Wire Shelf

Round

Hole

2

• With cart positioned as shown, align holes on cart with those on the smoke chamber bottom.

• Attach the smoke chamber using four 1/4-20x1-3/4” screws and four nuts per leg.

1/4-20 flange

• Tighten all hardware.

AA

Long Leg

Connect Leg Sections

(Repeat for Other Side)

1

Short Leg

(with Axle holes)

3

Attach Leg Braces

(Repeat for Other Side)

Smoke Chamber

Lid not shown for clarity.

3

• Attach knockout cover to the firebox chamber using two 8-32 x 1/2 screws and two 8-32 keps nuts.

• With smoker turned onto its right side, lower the firebox over the opening on smoke chamber as shown. Align the holes in the smoke chamber to those on the firebox and insert six 1/4 - 20 x 3/4 hex head screws and washers.

• Attach six 1/4 - 20 flange nuts to the backs of each firebox screw and tighten.

Check to be sure that all screws and nuts used so far are fully tightened.

• Have someone help you stand the unit in the upright position.

4 • Attach smokestack

1/4 - 20 x 1/2 screws

1/4 - 20 flange nuts .

using two and two

• Attach front shelf using three

1/4 - 20 x 3/4 screws

1/4 x 20 flange nuts.

and three

2 Shelf Attachment

1

Knockout

Cover

Lid removed for clarity.

Firebox

Smoke Chamber

(Left Side)

Lids not shown

1 for clarity.

1 Attach

Smokestack

2 Attach

Front Shelf

5 • Insert wire and cast iron grates as shown.

Lids removed for clarity.

6

• Hang the grease can holder under the smoke chamber on right side. Enter through large hole first.

• An empty soup can is recommended to hang from grease can holder.

Grease Can Holder

HARDWARE LIST

Hardware is shown actual size. You may have spare hardware after assembly is complete.

#8-32

Keps Nut

Qty. 2

#8-32 x 1/2

Machine Screw

Qty. 2

1/4-20x3/4”

Hex-Head

Machine Screw

Qty. 8

1/4-20x1-3/4”

Machine Screw

Qty. 12

1/4-20x1/2”

Machine Screw

Qty. 2

1/4-20

Reverse Lock Nut

Qty. 2

1/4-20

Flange Nut

Qty. 23

1/4-20

Flat Washer

Qty. 10

1/4-20x 3/4”

Machine Screw

Qty. 3

WARNING

MOST SURFACES ON THIS UNIT ARE HOT WHEN IN USE.

USE EXTREME CAUTION. KEEP OTHERS AWAY FROM UNIT.

ALWAYS WEAR PROTECTIVE CLOTHING TO PREVENT INJURY.

Limited Warranty

New Braunfels Smoker Co. warrants this grill/smoker for replacement or repair of parts and/or workmanship for a period of ninety (90) days . Paint is not warranted and will require touchup.

These limited warranties are made exclusively to the original customer presenting proof of purchase. These warranties are limited to non-commercial residential use only. Any returned goods must be shipped prepaid. These warranties do not cover normal wear and tear or damages resulting from abuse or misuse. This warranty excludes incidental or consequential cost due to damages or losses or property of any nature.

NOTICE: Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other legal rights which may vary from state to state.

For further information, contact the New Braunfels Smoker Co., toll free at 1-800-232-3398.

Before you begin . . .

Familairize yourself with the major components and controls of the unit.

Smokestack

Damper

Firebox

Firebox

Damper

Smoke

Chamber

With any type of live fire cooking, allow enough time to build a fire and get the grill/smoker up to temperature.

Build a fire using either charcoal briquettes, lump charcoal, or wood chunks. Briquettes offer a very good source of heat, and are readily available in the marketplace. Most briquettes are manufactured using a combination of wood charcoal, coal powder, and a processing binder. Lump charcoal is a premium form of charcoal because it is made of only wood. Lump charcoal burns hotter and longer than briquettes, and imparts no chemical flavors to the food being cooked. For a more robust smoke flavor using briquettes or lump charcoal, try adding several wood chunks to the fire. Wood chunks are available in a variety of natural flavors, and can be used alone or in addition to charcoal. As a general rule, any hardwood that bears a fruit or nut is suitable for cooking. However, different woods have very different tastes.

Mild Flavor

Pecan

Apple

Medium Flavor Heavy Flavor

Hickory

White Oak

Mesquite

Blackjack Oak

Peach Cherry Red Oak

Experiment with different woods to determine your personal favorite, and always use well-seasoned wood. Green or freshcut wood can turn food black, and tastes bitter.

Grilling

is a method of cooking directly over a fire, for foods such as steaks, hamburgers, and hot dogs. Cooking temperatures for grilling ranges from approximately 350° to

550°. Due to the high temperatures and direct proximity to the fire, this type of cooking requires close attention.

Barbequing

is accomplished by using indirect heat, with a temperature range from approximately 225° to 350°. Using an offset firebox design, only the heat and smoke flow through the smoke chamber, cooking the food without direct contact with the fire. This method is ideal for chicken, ribs, fish, and vegetables.

Slow Smoking

can also be done with the offset firebox design, using indirect heat and smoke. Similar to barbequing, the food is placed in the smoke chamber, with the fire in the firebox. However, slow smoking occurs in a temperature range of approximately 140° to 225°, and requires an extended cooking time. This type of cooking is ideal for turkey, ham, or sausage.

Prior to cooking on your grill/smoker , the following steps should be taken to season the interior steel and cast iron grates.

This will seal the inside surfaces with wood smoke and resin, helping to prevent corrosion.

First , brush all interior surfaces and cast iron grates with vegetable oil.

Next , build a small fire on the fire grate inside the firebox, being sure not to lay coals against the walls. After the fire becomes established, close both lids and position both dampers approximately 1/4 open. Sustain this fire for at least 2 hours.

The unit is now ready for cooking!

Grilling

Position both fire grates in the smoke chamber. Build a fire on top of the fire grates using either charcoal briquettes, lump charcoal, or wood chunks. Keep the smoke chamber lid open, and both dampers open, until the fire has established itself and is ready for cooking. Spread out coals as required, insert cooking grates, and start grilling. Remember, grilling is done over the top of the fire. Use the dampers to regulate the fire and heat. Open the dampers to increase temperature; close dampers to decrease temperatures. The smoke chamber door can remain open or closed. Refer to recipes for required cooking times and temperatures.

Maintenance

When finished cooking, and the unit has adequately cooled, clean out all remaining ashes. Ashes collect moisture, which can lead to premature rusting and decay. Periodically coating the interior surfaces and cooking grates with vegetable oil will aid in the protection of your unit. Also, occasional touch up of the exterior paint will be required. Black, high-temperature spray paint is recommended. Never paint the interior of the unit.

Barbequing and Slow Smoking

Position both cooking grates in the smoke chamber. Position one fire grate in the firebox. Build a fire on this fire grate using either charcoal briquettes, lump charcoal, or wood chunks.

Keep the firebox lid open, and both dampers open until the fire is established. Then, close the firebox lid (both lids should now be closed) and you will begin to see smoke flow from the smokestack. Adjust both dampers until the desired smoker chamber temperature is achieved. Open the dampers to increase temperature; close the dampers to decrease temperatures. This process of adjusting the temperature can take several minutes. Once the proper setting is obtained, only occasional attention is required. Now, place the food in the smoke chamber. Remember, this is indirect cooking, so the fire is in the firebox, and the food is placed in the smoke chamber.

Keep both lids closed while cooking to prevent unnecessary loss of heat and smoke. Refer to recipes for required cooking times and temperatures. Add charcoal or wood chunks as necessary to maintain the fire.

TOLL FREE 1-800-232-3398

Visit our web site at www.nbsmoker.com