If you’re a passionate backyard chef or smoking enthusiast, you’ve likely come across the decision point: should you stick with propane or upgrade your smoker to run on natural gas? Converting a propane smoker to natural gas is a practical, cost-effective, and convenient choice—especially if you have access to a natural gas line at home. Not only can it eliminate the hassle of running out of propane mid-smoke, but it also provides a steady, uninterrupted fuel source that enhances your cooking experience.
This comprehensive guide will walk you through everything you need to know about converting a propane smoker to natural gas. We’ll cover the benefits, the tools and parts you’ll need, a detailed step-by-step process, safety precautions, and expert tips to ensure success. Whether you’re a DIY veteran or a beginner, this guide will equip you with the knowledge to make your smoker more efficient and eco-friendly.
Why Convert Your Propane Smoker to Natural Gas?
Before diving into the conversion process, it’s important to understand why many smokers are making the switch. Natural gas doesn’t just offer convenience; it brings several long-term benefits.
Lower Long-Term Operating Costs
Propane tanks require frequent refills, which can be expensive. On average, natural gas costs significantly less per BTU than propane, especially if you already have a gas line hooked up to your home. Over time, the savings add up—making this conversion a smart financial move.
Continuous Fuel Supply
With propane, you’re always at risk of your tank running out during a long smoking session, such as when preparing brisket or pork shoulder. Switching to a natural gas line ensures an infinite fuel supply, allowing for uninterrupted cooking, even for marathon 12+ hour smokes.
Environmental and Efficiency Benefits
Natural gas burns cleaner than propane, emitting fewer greenhouse gases. It’s also considered a more sustainable energy source, especially when compared to bottled propane that requires transportation and manufacturing. For environmentally conscious grillers, this switch aligns with greener practices.
Convenience and Ease of Use
No more hauling heavy tanks, scheduling deliveries, or guessing when fuel will run out. Once your smoker is connected to your natural gas line, all you need to do is turn on the valve—there’s zero setup involved with each use.
Understanding the Basics: Propane vs. Natural Gas
To convert your smoker successfully, it’s crucial to understand the fundamental differences between propane and natural gas. These differences aren’t just about fuel source—they affect pressure, pipe size, and burner performance.
BTU Output and Energy Density
Propane has a higher energy content per cubic foot than natural gas. Specifically:
- Propane: ~2,500 BTUs per cubic foot
- Natural Gas: ~1,000 BTUs per cubic foot
This means natural gas must flow at a higher volume to produce the same heat output. The conversion process must compensate for this difference.
Gas Pressure and Orifice Size
Propane typically operates at a pressure of around 11 inches of water column, while natural gas runs at about 7 inches. Because natural gas requires a higher flow rate to maintain equivalent heat, the orifice (the hole through which gas passes to the burner) must be larger. Using a propane orifice for natural gas would result in insufficient fuel flow, reducing your smoker’s efficiency and temperature capability.
Available Hookups and Piping
Most homes have natural gas lines for heating or cooking. However, the smoker will need a dedicated outdoor gas line. You may need to run a flexible stainless steel gas line from your house to your smoker’s location—a task that may require professional assistance depending on local codes.
Is Your Smoker Compatible with Natural Gas Conversion?
Not all propane smokers can be converted. Before proceeding, assess your smoker model carefully.
Check the Manufacturer’s Guidelines
Some manufacturers explicitly state that their smokers are not convertible. Always refer to the user manual or contact the company directly. Brands like Weber, Masterbuilt, and Lang may offer authorized conversion kits—using these is the safest approach.
Look for a Conversion Kit
Many companies sell certified natural gas conversion kits specifically designed for their models. These typically include a new orifice, regulator, and hose. Using a proper conversion kit greatly increases safety and performance.
Evaluate Burner Design and Ventilation
Ensure your smoker’s burner can handle the different combustion characteristics of natural gas. Natural gas burns slightly cooler and requires more oxygen. Adequate airflow through ventilation ports is essential to avoid incomplete combustion, which can lead to soot production and carbon monoxide buildup.
Tools and Materials You’ll Need
Proceeding without the right tools can result in leaks, inefficiencies, or even dangerous outcomes. Gather everything before starting.
Essential Tools
- Adjustable wrench or gas-rated wrench
- Pipe thread sealant (yellow Teflon tape designed for gas lines)
- Screwdrivers (flathead and Phillips)
- Wire brush or orifice cleaning tool
- Multimeter or manometer (optional, for pressure testing)
- Gas leak detection solution or soapy water
Required Materials
- Natural gas conversion kit (or appropriate orifice and regulator)
- Flexible stainless steel gas hose (UL-listed for natural gas)
- Gas shutoff valve (ball valve, outdoor-rated)
- Flare or compression fittings (to connect hose to house line)
- Replacement burner cap (if needed)
Note: If you don’t have a natural gas shutoff valve near your smoker, installing one is highly recommended for safety.
Step-by-Step Guide to Converting Your Propane Smoker to Natural Gas
Now that you have the background knowledge and materials, it’s time for the actual conversion. Follow these steps carefully.
Step 1: Turn Off and Disconnect the Propane Supply
Before doing any work, close the propane tank valve and disconnect the hose. Make sure the smoker’s internal valves are turned off. Move the smoker away from walls or flammable materials to provide clearance.
Step 2: Remove and Clean the Burner Components
Access the burner assembly—this usually involves removing a metal plate or access panel. Carefully take out the burner tube and set it aside. Use a wire brush or compressed air to clean any debris from the burner ports.
Tip: Check the burner for corrosion or clogs. If it’s damaged, replacement may be necessary before conversion.
Step 3: Replace the Orifice
The orifice is the small metal fitting at the end of the gas valve that controls fuel flow. Propane orifices are smaller to regulate higher-pressure flow.
- Locate the current orifice (it screws into the gas valve).
- Use a small wrench to remove it carefully. Keep the old orifice in case you ever revert.
- Install the natural gas orifice from your conversion kit. Apply gas-rated thread sealant to the threads before screwing it in. Tighten securely, but avoid over-tightening to prevent damage.
Orifice Sizing Guidelines
| Smoker BTU Output | Recommended Propane Orifice Size (inches) | Recommended Natural Gas Orifice Size (inches) |
|---|---|---|
| 10,000 BTUs | 0.030 | 0.062 |
| 20,000 BTUs | 0.038 | 0.078 |
| 30,000 BTUs | 0.045 | 0.092 |
| 40,000 BTUs | 0.052 | 0.108 |
Do NOT guess the orifice size. Use manufacturer specifications or consult an expert.
Step 4: Install a Natural Gas Regulator
Propane and natural gas require different pressure regulators. Propane regulators typically reduce pressure to around 11 in. W.C., while natural gas needs 7 in. W.C.
- Replace the old propane regulator with a natural gas-approved one.
- If your conversion kit includes a dual-stage regulator, install it according to instructions.
- Connect the regulator to the gas line using proper fittings and sealant.
Step 5: Connect to the Natural Gas Line
This step varies based on your setup. If you have an existing outdoor gas line:
– Turn off the house gas supply.
– Install an outdoor-rated shut-off valve if one isn’t already present.
– Use a UL-listed stainless steel flexible gas hose to connect the smoker to the valve.
– Apply thread sealant to all threaded connections.
Caution: Running a new gas line from your house may require a permit and licensed professional assistance. Always check local codes.
Step 6: Reassemble and Perform a Leak Test
Reinstall the burner and cover plate. Before igniting, perform a leak test:
- Mix water with a few drops of dish soap.
- Turn on the gas supply slowly.
- Apply the soapy solution to all connections, valves, and hoses.
- Bubbles indicate a gas leak. Tighten fittings or reseal threads as needed.
Repeat until no bubbles form. This step is critical for safety.
Step 7: Test the Smoker’s Performance
Now that everything is connected and leak-free, it’s time to test.
- Open the smoker’s gas valve.
- Light the burner and observe the flame.
- A proper natural gas flame should be mostly blue with slight yellow tips. Avoid lazy yellow flames, as these indicate incomplete combustion.
Check if the smoker reaches and maintains target temperatures (e.g., 225°F for low-and-slow smoking). Adjust airflow if needed for even heat.
Safety Considerations When Converting to Natural Gas
Safety should be your top priority throughout the conversion.
Know the Signs of a Gas Leak
Natural gas is odorless, but utility companies add a sulfur-like smell (rotten eggs) to help detection. If you smell gas:
– Immediately turn off the supply.
– Extinguish all flames and avoid creating sparks.
– Evacuate the area and call your gas provider or emergency services.
Always Use Approved Parts and Materials
Don’t improvise with plumbing parts not rated for gas. Misusing materials can lead to leaks, explosions, or carbon monoxide poisoning. Only use UL-listed hoses, regulators, and fittings.
Ensure Proper Ventilation
Never operate your smoker in a closed garage or enclosed space. Natural gas combustion produces carbon dioxide and small amounts of carbon monoxide. Adequate ventilation is essential for safety.
Have a Fire Extinguisher Nearby
Always keep a Class B fire extinguisher close when operating any gas-powered appliance. It’s a small investment for peace of mind.
Maintenance Tips After Conversion
Once converted, regular maintenance ensures long-term performance.
Inspect Gas Hoses Periodically
Check for cracks, kinks, or wear every few months. Replace the hose every 3–5 years, even if it appears fine.
Keep the Burner Clean
Soot and grease can clog burner ports over time. Clean the burner every 2–3 months with a brush and mild degreaser.
Monitor Flame Quality
A healthy flame is mostly blue. Yellow or flickering flames may mean incorrect air-to-gas ratio, blockages, or pressure issues. Address problems immediately.
Winter Care
In colder climates, condensation can form in gas lines. Ensure your line slopes slightly downward from your house to prevent water pooling.
When to Call a Professional
While DIY conversion is possible, some situations require professional help.
Running a New Gas Line
If your home lacks an outdoor gas outlet, a licensed plumber or gas technician should install one. This ensures compliance with local building codes and safety standards.
Pressure Testing
Some jurisdictions require pressure testing of new gas lines. Professionals have the tools and certifications to perform this safely.
Dealing with Older or Unfamiliar Models
If your smoker wasn’t designed for conversion or you’re unsure about compatibility, it’s better to consult an expert than risk a dangerous mistake.
Common Mistakes to Avoid
Even experienced DIYers make errors. Here are frequent pitfalls to watch for:
Using Propane Orifices with Natural Gas
This leads to low heat output and poor performance. Always use properly sized natural gas orifices.
Over-Tightening Fittings
Gas fittings are delicate. Over-tightening can crack or strip threads, causing leaks.
Neglecting Leak Testing
Skipping the leak test is a dangerous shortcut. Gas leaks are not only costly—they’re deadly. Always double-check.
Ignoring Manufacturer Warnings
Some smokers are built exclusively for propane. Converting them without approval may void warranties or create hazards.
The Environmental and Economic Payoff
Beyond convenience, consider the broader impact of your conversion.
Natural gas produces approximately 15–20% less CO₂ than propane per unit of energy. While not a zero-emission solution, it’s a step toward cleaner backyard cooking.
Economically, the average smoker using propane spends $200–$400 per year on fuel. Switching to natural gas could reduce that by 30–50%, depending on your local utility rates. Add in reduced tank exchange fees and the value of uninterrupted cooking, and the return on investment becomes clear within 1–2 years.
Final Thoughts: Is Converting Your Smoker Worth It?
Converting a propane smoker to natural gas is one of the smartest upgrades a serious backyard chef can make. The combination of continuous fuel supply, reduced operating costs, and environmental benefits offers real value. While the process requires attention to detail and a commitment to safety, the rewards are tangible: longer smokes, smoother operation, and fewer interruptions.
If you have access to a natural gas line and your smoker supports conversion—either through official kits or through safe DIY adaptation—the answer is almost certainly yes. Invest the time, do it right, and you’ll enjoy years of consistent, reliable smoking with the simple twist of a knob.
Whether you’re smoking ribs for Sunday dinner or prepping competition-worthy brisket, switching to natural gas ensures your fuel keeps up with your passion. So grab your tools, follow the steps above, and transform your smoker into a seamless, efficient cooking machine.
Now, fire it up—and happy smoking!
Why would someone want to convert a propane smoker to natural gas?
Converting a propane smoker to natural gas can offer several practical benefits. Natural gas is often more convenient and cost-effective, especially if your home already has a natural gas line. Unlike propane, which requires refilling or exchanging heavy tanks, natural gas provides a continuous supply as long as it’s connected to your home’s gas system. This eliminates the need to monitor fuel levels and run out of gas mid-smoke, making long smoking sessions easier to manage.
Additionally, natural gas burns cleaner than propane, producing fewer emissions and reducing soot buildup on your smoker components. From an environmental standpoint, natural gas is considered a greener option. For homeowners who smoke food frequently, the long-term savings from using natural gas can be significant, and the permanent hook-up creates a more streamlined outdoor cooking setup. These factors make conversion appealing for dedicated barbecue enthusiasts.
Is it safe to convert a propane smoker to natural gas on my own?
Converting a propane smoker to natural gas can be safe if proper procedures and safety guidelines are followed. Many manufacturers design their smokers to be convertible, and some even offer official conversion kits. When using a kit made specifically for your model, you reduce the risk of gas leaks, improper pressure settings, or combustion issues. However, it’s critical to turn off the gas supply and work in a well-ventilated area when making any modifications.
That said, any work involving gas lines carries inherent risks. A poorly executed conversion may lead to gas leaks, inefficient burning, or even fire hazards. If you’re uncomfortable working with gas appliances or aren’t confident in your ability to follow detailed instructions, it’s best to consult a qualified gas technician. Safety should always be the top priority—ensuring that all connections are tight, pressure is regulated, and the unit operates correctly after conversion.
What tools and materials are needed for the conversion?
To convert a propane smoker to natural gas, you typically need a conversion kit designed for your specific model. These kits usually include a natural gas orifice (or multiple orifices), a gas connector hose rated for natural gas, a regulator compatible with natural gas pressure (usually 7 inches water column), and installation instructions. Additional tools commonly required are wrenches, screwdrivers, thread seal tape (rated for gas), and a soapy water solution for leak testing.
It’s also helpful to have safety gear like gloves and safety glasses during the process. A multimeter or manometer may be needed if you want to precisely check gas pressure, though this is more advanced. Always verify that your smoker’s burner and other components are compatible with natural gas since some parts may need adjustment or replacement. Having the right tools ensures a smooth, safe conversion and reduces the likelihood of errors.
How do you adjust the orifice size when converting to natural gas?
Propane requires a smaller orifice than natural gas because it is delivered at a higher pressure and has a higher energy density. When converting, you must replace the propane orifice with one that has a larger diameter to allow the lower-pressure natural gas to flow adequately for proper combustion. Using an undersized orifice will result in weak flames and uneven heating, while an oversized one can cause excessive gas flow and safety concerns.
The correct orifice size is usually specified in the conversion kit or the manufacturer’s guide. It’s essential to remove the original orifice carefully and thread in the new one using gas-rated thread seal tape to prevent leaks. After installing, always test the flame to ensure it’s steady, blue, and fully covers the burner without lifting or yellow tipping. Proper orifice sizing is crucial for both performance and safety during operation.
What are the differences between propane and natural gas pressure?
Propane is typically delivered to appliances at around 11 inches of water column, whereas natural gas operates at a lower pressure of approximately 7 inches of water column. This pressure difference means the regulator on your smoker must be designed or adjusted to accommodate natural gas to ensure safe and optimal performance. Using a propane regulator with natural gas can lead to inadequate gas flow and poor heating results.
Because of this difference, the conversion process usually involves replacing the existing regulator with one calibrated for natural gas. Some conversion kits include a new regulator, while others may require you to purchase one separately. Matching the correct pressure ensures that the smoker heats properly, maintains consistent temperatures, and avoids potential dangerous situations like gas buildup or improper combustion.
How do you test for gas leaks after completing the conversion?
After installing the natural gas components, it’s essential to test for leaks before lighting the smoker. Start by applying a soapy water solution to all gas connections, including the regulator, hose, orifice, and any joints. Slowly turn on the gas supply and observe these areas closely. If bubbles form, it indicates a gas leak that must be addressed immediately by tightening the connection or reapplying thread seal tape.
Never use a flame or electronic lighter to check for leaks. Once you’ve confirmed no bubbles appear, light the smoker and check again under operating conditions, as thermal expansion can sometimes reveal hidden leaks. If in doubt, shut off the gas and consult a professional. Regular leak testing after future maintenance is also recommended to maintain long-term safety.
Can all propane smokers be converted to natural gas?
Not all propane smokers are suitable for conversion to natural gas. Some models are designed specifically for propane and lack the necessary components or structural support for natural gas hookups. The burner design, gas line diameter, and internal pressure tolerances may not be compatible, making conversion impractical or unsafe. Always consult the manufacturer’s documentation to determine if your model supports conversion.
If a manufacturer offers an official conversion kit for your smoker, the process is generally reliable and safe. However, if no kit is available, adapting the smoker becomes more complex and may void your warranty. In such cases, professional advice is recommended. Attempting to force a conversion on an incompatible unit can lead to inefficient operation, increased risk of gas leaks, or permanent damage to the smoker.