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    Home » Pit Boss Guides

    Published: Aug 23, 2023 · Modified: Apr 2, 2024 by Mads Martigan · This post may contain affiliate links · Leave a Comment

    How to Remove the Safety Grid on a Pit Boss Hopper

    Jump to Recipe Jump to Video Print Recipe

    The Pit Boss pellet grill hopper grid is a safety feature that most people find unnecessary and cumbersome. We show you how to remove the grid and plug the holes to prevent water from seeping into the hopper.

    lifting off the hopper safety grid

    The Pit Boss hopper safety grid is a feature the company adds to prevent someone from putting their hand down into the auger and becoming injured.

    While this feature can be helpful if you have small children, adults can typically manage to keep their hands away from the auger. For these adults, the grid is more of a nuisance.

    Here we show you how to remove the hopper grid and plug the holes so that you protect your hopper from water.

    Jump to:
    • Why Would you Want to Remove the Hopper Grid?
    • DISCLAIMER on Removing the Safety Grid
    • Video
    • Materials
    • Instructions

    Why Would you Want to Remove the Hopper Grid?

    After each cook, you want to empty the hopper of pellets into an airtight pellet bucket and store them indoors in a cool, dry place.

    Leaving pellets in the hopper can cause them to absorb humidity, which can affect how much smoke they will produce. These pellets can also jam the auger.

    Oklahoma Joe's 5159038W01 Pellet Bucket Kit, Black
    Oklahoma Joe's 5159038W01 Pellet Bucket Kit, Black
    • Store up to 20 pounds of hardwood pellets in the heavy-duty plastic pellet bucket.
    • Weatherproof, airtight lid protects pellets from the elements, keeping them fresh and dry
    • Wire-mesh filter separates wood dust from the pellets for a clean burn
    • Heavy-duty plastic scoop to easily transfer pellets
    Check Price on Amazon

    To empty the hopper, you need to push the pellets to the back of the hopper so that they fall out the drain into your bucket. The grate makes this difficult.

    We typically use a long wooden paint stick to help guide the pellets to the drain, but the grate is in the way and makes this much harder than it needs to be.

    Also, we like to make custom blends of pellets when cooking food.

    4 Oklahoma Joe's pellet bucketsWhen making custom blends, we pour pellets from multiple buckets into the hopper, but they need to be mixed.

    Again, a wooden paint stick can help do this, but the grid makes this more difficult.

    One thing to consider is that removing the grid will also eliminate the place for the Pit Boss temperature probe.

    This does not bother us, as we have found the probe to be inaccurate. We always use our own internal temperature probe in the meat we are cooking.

    ThermoPro TP-20 500FT Wireless Meat Thermometer
    • Extended Remote Range: Wireless thermometer with dual probes optimizes its wireless range from up to 500FT to monitor your food or oven/grill/smoker temperatures
    Check Price on Amazon

    If you DO use the Pit Boss temperature probe, no worries.

    Once you follow this method to remove the grid, you can set it back in the hopper to hold the probe and simple lift it out when you need to fill or empty the hopper.

    DISCLAIMER on Removing the Safety Grid

    Please note, the reason for the grid is to prevent someone from putting their hand down into the auger and getting hurt. Pit Boss does not recommend removing this safety feature.

    If you have small children, we highly encourage you to keep the grid in place.

    We have found a wooden paint stick works relatively well to mix and distribute the pellets in the hopper when the grate is intact. These are available for free in the paint section of most hardware stores or in bulk online.

    If you decide to remove the hopper grate, you do so at your own risk. Mad Backyard does not assume any liability for resulting injuries.

    Never put your hands into the hopper when the Pit Boss is plugged in.

    When the Pit Boss is on, the auger can move at any time. A wooden paint stick may be used to easily push the pellets toward the auger when the Pit Boss is on.

    If you're still set on removing the grid, here is how to do it.

    Video

    Rather WATCH than read? Check out our YouTube video to show you exactly How to Remove the Safety Grid from the Pit Boss Hopper.

    Materials

    Please note the sizes of the wing nuts and washers fit the Pit Boss 1150 Pro. Your model Pit Boss may require a slightly different size wing nut/washer. These materials are available at most local hardware stores or online.

    • Philips head screwdriver
    • Six #8-32 wing nuts
    • Six #8 diameter flat washers
    binifiMux 60pcs 8-32 Wing Nuts Butterfly Nuts, Carbon Steel Zinc Plated
    binifiMux 60pcs 8-32 Wing Nuts Butterfly Nuts, Carbon Steel Zinc Plated
    • - Material:Carbon Steel; - Quantity:60pcs;
    • - Features: Easy to install
    Check Price on Amazon

    Instructions

    Open the hopper.

    Locate the 6 screws that hold the safety grid (or safety grate) in place.

    Two are on the front of the hopper, two are on the left side, and two are on the back.

    Pit Boss Hopper with grid intact

    Using a Phillips head screwdriver, turn one of the screws to loosen it and carefully remove the screw and washer.

    Screwdriver unscrewing hopper grate screw
    Removing hopper grid screw and washer

    Set both aside and repeat with the remaining 5 screws.

    We do NOT recommend using an electric screwdriver, as it could scratch the surface of your Pit Boss.

    hopper grate screws and washers on a flat surface

    The grid is held in place through tension.

    To remove it, stand behind the Pit Boss hopper and place both hands on the front of the grid where the metal goes up into a triangle shape.

    pulling up on hopper safety grid

    Pull in and up to remove the pellet grate.

    removing the hopper safety grid

    To plug the holes, you will need 1 metal washer and 1 wing nut per hole.

    wing nut and washer in a hand
    FASTENER TREE #8 x ⅜" Flat Washer 304 Stainless Steel SAE Washer for Screws Bolts 100PCS
    FASTENER TREE #8 x ⅜" Flat Washer 304 Stainless Steel SAE Washer for Screws Bolts 100PCS
    Check Price on Amazon

    Replace one screw with the original black washer on the outside. On the inside, add a silver washer.

     placing metal washer over screw for pit boss hopper

    Then screw on the wingnut. Tighten it by hand.

    Screwing on wing nut for pit boss hopper

    Repeat with the 5 remaining screws.

    wing nuts and washers screwed in on hopper

    You can see here the six wing nuts.

    aerial shot pit boss hopper with safety grid removed

    You can then store the grid in a safe place in case you ever need to reinstall it.

    Alternatively, you can set it on top of the wing nuts and keep it in the hopper, easily lifting it out as needed.

    When you need to move pellets around, we recommend using a wooden paint stick rather than putting your hands into the hopper.

    Without the pellet grid in place, the paint stick is much easier to move around to stir and redistribute pellets.

    moving pellets towards auger with paint stick

     

    lifting the hopper grid off of the pit boss hopper

    How to Remove the Pit Boss Safety Grate

    Mads Martigan
    Learn how to remove the Pit Boss safety grid and replace the holes so water does not get into the hopper.
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    Cook Time 10 minutes mins
    Total Time 10 minutes mins

    Equipment

    • 1 Philips Head Screwdriver

    Ingredients
      

    • 6 #8-32 Wing Nuts
    • 6 #8 diameter Flat Washers

    Instructions
     

    • Open the hopper. Locate the 6 screws that hold the safety grate in place. Two are on the front of the hopper, two on the left side, and two on the back.
      Pit Boss Hopper with grid intact
    • Using a Philips head screwdriver, turn one of the screws to loosen it and carefully remove the screw and washer. Set both aside and repeat with the remaining 5 screws. We do NOT recommend using an electric screwdriver as it could scratch the surface of your Pit Boss.
      Screwdriver unscrewing hopper grate screw
    • The grate is held in place through tension. To remove it, stand behind the Pit Boss hopper and place both hands on the front of the grate where the metal goes up into a triangle shape.
      pulling up on hopper safety grid
    • Pull in and up to remove the grate.
      removing the hopper safety grid
    • To plug the holes, replace one screw with the original black washer on the outside. On the inside, add a silver washer and then screw on the wingnut. Tighten it by hand. Repeat with the 5 remaining screws.
      Screwing on wing nut for pit boss hopper
    • You can then store the grate in a safe place in case you ever need to re-install it.

    Video

    Keyword hopper, hopper grid, hopper grid removal, hopper removal, pellet hopper, pit boss hopper, pit boss hopper clean out, safety grate, safety grid
    Tried this recipe?Let us know how it was!

    More Pit Boss How-to Guides

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      How to Start a Pit Boss Pellet Grill: Step-by-Step
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      How to Install and Remove the Top Rack of a Pit Boss Pellet Grill
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      How to Light a Pellet Tube for More Smoke Flavor

    About Mads Martigan

    Mads is the founder of Madbackyard.com and has been a BBQ and Grilling enthusiast for the past 15 years. He loves to write about and make videos on smoking and barbecuing all kinds of great food.

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    Robert "Mads" Martigan, the founder of Mad Backyard

    Hi, I'm Mads, the founder of Mad Backyard and an avid outdoorsman, barbecue/smoker buff, and pellet grilling enthusiast who loves to share my passion for outdoor living and outdoor cooking with the world.

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