Old Smokey electric smoker emits a strong burning plastic or electrical smell when heating.

Safety first: Unplug the smoker immediately if you smell burning plastic or see smoke from areas other than the vent. Do not continue operation until the source is identified.

Steps to locate and correct burning odors:

• 1. Inspect the heating element: After cooling, look for grease, foil, or other debris stuck to the element. Clean gently with a non-abrasive pad.
• 2. Check nearby wiring: Remove the access panel and inspect wires near the element and thermostat. Look for melted insulation or discoloration. Replace any damaged wiring with high-temperature wire and secure it away from hot surfaces.
• 3. Examine the control area: Open the control housing and sniff for burnt odor. Look for darkened components or melted plastic on the control board or thermostat.
• 4. Burn off manufacturing oils (new units): For a new Old Smokey smoker, run an initial seasoning cycle empty at medium-high temperature for 1–2 hours to burn off protective oils. Some odor is normal during this first use.
• 5. Replace failing components: If a specific component (wire, thermostat, control board) shows signs of overheating, replace it before further use.

Warning: Persistent burning smells indicate a serious issue. Do not ignore them or continue cooking until fully resolved.