Please excuse the long post but I am hoping to get some input from the PBC fans on this site. I occasionally post comments to the BBQ Brethren site and it is not uncommon for folks to respond that they could build one for under $100, and that the PBC is nothing more than a smaller UDS. It gets me worked up a bit and I usually try to respond that that PBC is not just any old UDS, but I usually don’t try to refute the claim that it can be built much cheaper than what you would spend on a PBC.
Well I got to thinking about the cost issue a bit more and realized that especially with the new porcelain coated version that it might be very difficult to build a PBC for much less than what Noah sells it for. I actually talked to him the other day to help better understand the build process and what it might cost the do-it-yourselfer to try and build one himself. Below is what I put together and am looking for your comments or suggestions. I might eventually post this to BBQ Brethren site, but thought you guys might be open to helping me identify anything I might have overlooked or misstated so that I can make my arguments even better. Looking forward to any feedback you may have!
"Pit Barrel Cooker? Heck I could build one for less than $100!!!”
It is not uncommon for owners of the Pit Barrel Cooker, who are justifiably proud of their cookers, to be told by friends that although it might cook some good food, they could build the same thing for $50 - $100. Well folks, just because you say it that doesn’t make it so.
Granted, people have been building Ugly Drum Smokers (UDS) for years, and they are quite amazing and inexpensive cookers. However, as Amazingribs.com and hundreds of other reviewers have stated, the PBC is not just a regular UDS. There is something about the 30 gallon drum size (vs the standard 55 gallons), the hanging of the meat, the premeasured coal basket, and the very precise venting that makes the food that comes of the PBC out of this world.
But then you may say, “well I can build a UDS with a 30 gallon drum, buy some rebar and meat hooks and I can still spend less than $100." Well let’s look at that statement a little closer, shall we? I’ll review each component of Pit Barrel Cooker package and see what it might cost to duplicate. And let’s assume for the most part that you will be using new parts. After all, the PBC does not use recycled drums, grates, etc., so you should factor that into your cost to build. This should be fun.
New 30 Gallon Drum: Pit Barrel uses new 18 gauge barrels built to their specs. They do not use adhesive to affix the bottom of the drum to the sides, and this is an important consideration as you will see below in the porcelain coating section. We’ll set this issue aside for a moment and assume you will buy a standard drum. One of the best prices you will find online for an open lid drum is on Amazon: $71.95 + $34.54 shipping. Total: $106.49
http://www.amazon.com/SKOLNIK-Carbon-Steel-gallons-1-2mm/dp/B006P5ROWQ/ref=sr_1_3?ie=UTF8&qid=1430958200&sr=8-3&keywords=30+gallon+drum
Grill Grate 18 inches. Amazon with free shipping: $16.99
http://www.amazon.com/Weber-7432-Cooking-Grate/dp/B000WEPFOK/ref=sr_1_2?ie=UTF8&qid=1430957286&sr=8-2&keywords=weber+grill+grates+for+18.5+kettle
Stainless Steel Hooks: Pack of 8. PBC hooks are custom made, and are sturdy and very well made. The closest item I could find online was at Lions Deal Restaurant and Office Wholesale: $17.52 + $10.44 Shipping. Total: $27.96
http://www.lionsdeal.com/jr-9116.html
Fire Basket: You could make or buy an expanded metal basket for about $40 - $60, but the PBC basket is made of a heavy gauge steel ring and steel rod grate. A very conservative estimate to build your own or have a welder make one for you is $50.
Horseshoe Stand: Granted you do not need a stand for your barrel but to compare apples to apples we need to estimate what it would cost to build one yourself or have one made for you. Again, a conservative estimate would be about $15.
Hook Tool and Rebar: Nothing too fancy here, but let’s say a total of $8.
Two Jars of 4.7 OZ Rub: These are included in your Pit Barrel Kit so we should include these in your estimate. They retail for $7.95 at the Pit Barrel website but let’s reduce the price a bit as you may be able to find two comparable bottles of rubs for a total of $10.
Porcelain Finish: This is where it gets really tricky. It is pretty safe to say that no do-it-yourselfer has the equipment, materials and expertise to apply a high quality porcelain coat to the barrel and lid. It is also doubtful that you could find someone in your area who could do the job. In fact, it took months of searching to find a company that was up to the task, and then it took countless test samples to get the process just right.
During the testing process it was determined that the barrels you will find at retail or in the scrap yard are not designed for porcelain coating. The adhesive used to affix the bottom on standard drums will not hold up to the 1550 degrees heating process used in applying the coating. The glue will blow out and prevent the porcelain from adhering and will create a very messy looking coating. Pit Barrel Cookers have always been made without the adhesive bottom so this was a very happy accident. But for the sake of argument, let’s say you could somehow find a company capable of doing the coating and you could find a drum that is adhesive-free. What would you think this would set you back? We can’t imagine you could do it for less than $150. But to be generous, let’s say it would only cost you$100.
Total Estimated Investment (excluding your time and any gas you use going to the store to purchase supplies): $334.44.
Cost of the Pit Barrel Cooker: $299.00. So the fine folks at Pit Barrel Company have saved you $35.44.
And think of the time and frustration you save. You have a choice: You could order your PBC today and be cooking some of the tastiest food you will ever have within just a few short days. Or you can think about building one yourself and most likely never get around to it. Even if you do get up the energy to take on this daunting project, think of the long hours of labor, the headaches in trying to source your parts and specialized labor (remember that porcelain coating), and the fact that you many never know the pleasure of eating the juiciest and most favorable smoked chicken ever. It’s your call, but I think I will be calling the Pit Barrel Company.