How To Assemble The Pit Boss Pro Series 820

So you’re thinking about getting a Pit Boss grill, but you’re not sure you have the skills to assemble it? Should you get it pre-assembled or assemble it yourself? In this article, I’m going to show you how to assemble the Pit Boss Pro Series 820, even if you don’t have any skills.

These are the steps for assembling the Pro Series 820, but these steps will be pretty much the same for any series of smoker grill you buy.

stand the Pit Boss Grill 820 on the legs

How To Assemble The Pit Boss Grill?

Unfortunately, I didn’t create a video on my personal experience of putting it together, because I wasn’t sure how long it was going to take.

It took us about an hour to put the grill together from scratch.

These are the exact steps we took when assembling our Pit Boss Pro Series 820 electric smoker grill.

How To Assemble The Pit Boss Pro Series 820

Step-by-step instructions will walk you through on how to assemble the Pit Boss Pro Series electric smoker grill.

These general steps will work for any electric smoker, the only difference will be the parts that come with the smoker grill.

Prep Time 20 minutes
Active Time 2 hours
Total Time 2 hours 20 minutes


  • Everything That came with your Pit Boss Grill Pro Series 820. Refer to your manual to see what parts came with your electric smoker grill.


  • Painters Tape
  • Phillips Screw Driver
  • Drill


Take The Pit Boss Pro Series 820 Out of The Box

take the grill out of the box

Once the grill arrives, take it out of the box and choose an open spot where you'll be putting the grill together. We used our driveway to put it together.

We cut the cardboard box into several and spread it out on the driveway to prevent any scratches or scuffs on the electric smoker grill.

Inspect For Any Missing Parts

Before you begin assembling your Pit Boss Grill, make sure you check the box for any missing parts.

Every grill may be different, so be sure to check the owner's manual to see what parts you will need. Believe it or not, we were missing 2 washers, so we had to use some we had laying around in our backyard shed until we can get to Lowes Hardware.

Tilt The Electric Smoker Grill On Its Side

put the grill on it's side and put the legs on

Use the painters tape to keep the hopper lid closed, so it doesn't close on your fingers or keep flopping open.

You can also use the tape to keep the smoker lid closed until you've assembled it completely.

Mount The Wheels To The Legs

Look for the wheel axle pin, wheel axle washer, and wheel Cotter Pin to carefully mount the wheels to the legs.

Mount The Legs To The Main Barrel

Once the wheels have been mounted, it’s time to mount the legs to the barrel. You’ll want

Install The Bottom Shelf

put the bottom shelf on

Line the bottom shelf to the pre-drilled holes on the legs and use the screws, locking washer and washer to support the shelf to the legs.

Make sure that the flat surface of the shelf is facing the bottom of the grill.

Stand The Grill On Its Legs

stand the Pit Boss Grill 820 on the legs

Slowly stand the grill back up to finish putting it together. You will need two people to grab one end of the grill to ensure it doesn't keep rolling forward.

Secure The Lid Stopper

Next, secure the lid stopper onto the main barrel.

Attach The Side Shelf

Grab the side shelf from the box and line it up with the three holes on the side of the shelf. Use the tool hoks to secure to the self-clinching nut that is pre-mounted on the inside.

Use the screws, locking washers, and washer to fasten the shelf to the barrel from underneath the shelf.

Attach The Smoke Stack

Next comes the chimney or smokestack. Grab the chimney and chimney gasket and line it up to the chimney hole on the side of the barrel.

Secure it tightly with the screws, locking washers, and washers.

Once it's been secured properly, screw the chimney cap to the top of the chimney stack by screwing it all the way down.

Install The Front Shelf Brackets

Grab the front shelf brackets from the box and attach them to the front of the grill using the three screws. Install the screws halfway, until you get all three screws halfway and properly align the brackets.

Repeat the process for the other front bracket.

Mount The Front Bracket

Grab the front shelf and make sure that the Pit Boss branding side is face up. Line the shelf up and attache it it to the bushing screw, washer and nut. Repeat the process for the other side.

You should be able to lower and raise the shelf without any issues if it is attached properly.

Install The Cooking Components

The final step is to install the cooking components which consist of:

  1. Porcelain-Coated Cooking Grids
  2. Flame Broiler Main Plate
  3. Porecelain-Coated Main Plate
  4. Flame Broiler Slider

assembled Pit Boss grill pro series 820

Congratulations, you've completed the set up of your grill and you can proceed to the first burn off.


Depending on your skills of using a screwdriver and a drill, you may be able to assemble the electric smoker grill in less time.

However, I'd give myself at least 1.5 hours to ensure you have enough time to get it assembled properly.

References And Further Reading

PIt Boss Pro Series 820: Wood Pellet Grill & Smoker – Manual

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