Big Horn Grill Review: Is This the Ultimate Budget Pellet Smoker?
The world of outdoor cooking has been revolutionized by wood pellet technology. For years, brands like Traeger dominated the space, but often at a price point that made the average backyard griller hesitate. Enter Big Horn Outdoors. Known for robust construction and aggressive pricing, Big Horn has entered the chat with a pellet grill that promises the same “set it and forget it” convenience without the premium markup.
But in a market flooded with budget-friendly options, how does the Big Horn stand up? Does it maintain temperature? Does it produce that coveted blue smoke? Or is it just a cheap imitation? If you are looking for the best barbecue grill on a budget, you need to know if cutting costs means cutting corners.
In this comprehensive Big Horn Grill review, we are deep-diving into the build quality, cooking performance, and overall value of the Big Horn Outdoors Pellet Grill. Whether you are aiming to smoke your first brisket or just want easy weeknight burgers, this guide will determine if Big Horn deserves a spot on your patio.
Product Overview: Big Horn Outdoors Pellet Grill
The Big Horn Outdoors Pellet Grill is designed for the versatility seeker. It markets itself as an 8-in-1 cooker: grill, smoke, bake, roast, sear, braise, barbecue, and char-grill. While this is a common marketing claim for pellet grills, the Big Horn backs it up with a heavy-duty steel construction that is surprisingly robust for its price tier.
It features a total cooking area of approximately 700 square inches (including the warming rack), a digital control center, and an automated electric feed system. It’s aimed squarely at the entry-to-mid-level user who wants to transition from charcoal grills or propane to the consistency of wood pellets.
Big Horn Outdoors Wood Pellet Grill & Smoker
Capacity: 700 Sq. In. | Hopper: 18 lbs | Temp Range: 180°F – 450°F
Check Price on AmazonDeep Dive: Features and Build Quality
Let’s strip away the marketing fluff and look at the nuts and bolts. A grill is only as good as its materials, and pellet grills, in particular, rely heavily on their electronic components.
1. Construction and Durability
Upon unboxing, the first thing you notice about the Big Horn grill is the weight. It utilizes heavy-gauge steel which helps with heat retention. Unlike some flimsy competitors where the lid feels tinny, the Big Horn lid has a reassuring “thud” when you close it. The powder-coated finish is designed to withstand high temperatures, though like all grills, we recommend a cover to prevent rust.
The legs and wheels are sturdy, which is crucial. Pellet grills are top-heavy due to the hopper and auger system. The all-terrain wheels make moving it across grass or uneven patio pavers relatively easy.
2. The Cooking Surface
You get 430 square inches of main cooking area and a secondary rack that brings the total to 700 square inches. The grates are porcelain-coated wire. While cast iron is often preferred for searing marks, porcelain-coated wire is much easier to clean and maintain. For indirect smoking—which is what this unit excels at—these grates are perfect.
3. Digital Control System
The brain of the operation is the digital controller. It allows you to set temperatures in 25-degree increments. While it lacks the PID (Proportional-Integral-Derivative) precision found in high-end models like Traeger or Pit Boss, the standard duty cycle controller is reliable. It reads the internal temperature and feeds pellets automatically to maintain your set point.
Note: The controller includes an LED readout that is visible in sunlight, solving a common complaint with older digital smokers.
4. Hopper Capacity
The hopper holds 18 pounds of wood pellets. This is slightly less than the standard 20lb bag of pellets you buy at the store, meaning you’ll have a little left over in the bag. However, 18lbs is sufficient for roughly 15-20 hours of smoking at low temperatures, covering even the longest brisket cooks.
Performance Evaluation: Smoking vs. Grilling
The biggest question for any hybrid unit is: does it actually grill, or is it just an outdoor oven?
Smoking Capabilities
This is where the Big Horn shines. We tested it with a rack of St. Louis style ribs. Setting the temperature to 225°F, the grill stabilized within 15 minutes. The smoke production was consistent—thin, blue smoke rather than heavy, billowing white smoke (which can taste bitter).
The convection fan circulates heat evenly, eliminating hot spots. This means you don’t have to rotate your meat constantly. For long cooks, like the ones described in our guide to the best smoker for ribs and brisket, consistency is key, and the Big Horn delivers.
Grilling and Searing
Can you sear a steak on it? The maximum temperature hits around 450°F. While this is hot enough to bake pizza or roast chicken, it struggles to provide a “steakhouse sear” compared to a propane grill or charcoal. This is a common limitation of the pellet grill vs gas grill debate.
To get a true sear on the Big Horn, we recommend using a cast-iron skillet inside the grill or investing in GrillGrates™ to amplify the surface temperature.
Ease of Use
The automated auger system removes the hassle of tending a fire. If you are comparing pellet smokers vs electric smokers, the pellet grill offers superior flavor due to real wood combustion, while maintaining the “plug and play” ease of electric units.
Startup: The auto-ignition works flawlessly. Just turn the dial to “Smoke,” wait for the roar of the fire, and then dial in your temp.
Pros & Cons Breakdown
| What We Love (Pros) | What Could Be Better (Cons) |
|---|---|
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Big Horn vs. The Competition
How does Big Horn stack up against the heavyweights like Traeger and Z Grills?
| Feature | Big Horn Outdoors | Z Grills 700 Series | Traeger Pro 575 |
|---|---|---|---|
| Price Range | Budget ($$) | Budget ($$) | Premium ($$$$) |
| Cooking Area | ~700 sq. in. | ~700 sq. in. | 575 sq. in. |
| Controller | Digital (Standard) | Digital (PID available on newer models) | WiFIRE (WiFi Enabled) |
| Hopper Capacity | 18 lbs | 20 lbs | 18 lbs |
| Max Temp | 450°F | 450°F | 500°F |
Big Horn vs. Z Grills
These are the most direct competitors. Both offer similar build quality and feature sets. Z Grills often runs aggressive marketing campaigns, but Big Horn typically wins on structural rigidity. If you want a slightly sturdier feel, Big Horn is the way to go.
Big Horn vs. Traeger
Traeger is the original. With the Pro 575, you are paying for the WiFIRE technology that lets you control the grill from your phone. If tech is important to you, Traeger wins. But if you just want to cook good food and save $400-$500, the Big Horn cooks just as well. For a deeper look at high-end comparisons, check out Pit Boss vs Traeger.
Maintenance and Expert Tips
To keep your Big Horn running for years, you need to treat it right. Here are some expert insights:
- The Burn Off: Before your first cook, you must perform a burn-off to remove manufacturing oils. Read our guide on how to season a new BBQ grill.
- Vacuum Ash: Unlike charcoal, pellets turn to fine ash that sits in the firepot. You need to vacuum this out every 3-5 cooks to prevent flame-outs.
- Keep Pellets Dry: Moisture ruins pellets, turning them into sawdust that jams the auger. Always store pellets in a sealed bucket.
- Grease Management: Line your grease bucket with foil for easy cleanup. Regular cleaning is a key maintenance requirement to prevent grease fires.
Also, invest in good accessories. A high-quality BBQ rub and a reliable meat thermometer are non-negotiable barbecue tools.
Frequently Asked Questions
Can I leave the Big Horn Grill outside?
While the Big Horn Grill is built with powder-coated steel, the electronic components (the controller and auger motor) are sensitive to moisture. It is highly recommended to use a waterproof grill cover and, if possible, store it under a patio roof or in a garage when not in use.
Does the Big Horn Grill need electricity?
Yes. All wood pellet grills require a standard electrical outlet to run the digital controller, the convection fan, and the auger motor. It consumes relatively low power, similar to a lightbulb.
How long does a hopper of pellets last?
The 18lb hopper on the Big Horn Grill will typically last between 15 to 20 hours at smoking temperatures (225°F). At high heat (450°F), pellet consumption increases, and a hopper may last 6-8 hours.
Can I use any brand of pellets?
Yes, you can use any brand of food-grade wood pellets. You do not have to use Big Horn branded pellets. Brands like Bear Mountain, Lumber Jack, or Traeger pellets will work perfectly fine.
Why is my Big Horn Grill not smoking enough?
Pellet grills produce the most visible smoke at lower temperatures (180°F – 225°F). Above 300°F, the fire burns cleaner and produces less visible smoke, though the flavor is still there. For extra smoke, consider using a smoke tube accessory.
Final Verdict: Should You Buy the Big Horn Grill?
The Big Horn Outdoors Pellet Grill is a standout performer in the budget category. It doesn’t try to dazzle you with WiFi apps or color touchscreens. Instead, it focuses on the fundamentals: heavy steel, consistent temperatures, and reliable feeding.
If you are new to smoking and want to experience the magic of wood-fired flavor without spending a fortune, this is an excellent entry point. It handles ribs, pork butts, and chicken with ease. While it won’t sear a steak like a high-heat electric grill or gas burner, its versatility as a smoker/baker/roaster makes it a valuable tool in any outdoor kitchen.
For the price, the build quality punches well above its weight class, making the Big Horn Grill a smart investment for the pragmatic pitmaster.
