A pellet smoker is the one grill on your patio that gets into real trouble when water gets where it should not. Pellets left sitting in a wet hopper absorb moisture, swell, and turn to a paste that jams the auger shaft. Paint chalks, plastic control panels fade, and the grease management system carries a film that smells for weeks. A cover is the cheapest insurance you will ever buy for that machine.
We spent weeks comparing the best grill covers for pellet smokers, matching fabrics, fits and closure systems against the shapes that actually sit on patios: Pit Boss cart grills, Traeger 22s and 34s, Camp Chef pellet models, Rec Tec cabinets, Z Grills and offset-style boxes. Ten covers made the cut, and every one of them earned its place by fitting a real smoker with a real chimney, hopper and leg clearance.
Two numbers did most of the sorting: fabric denier and warranty length. 600D polyester is the practical floor for a cover that will live outdoors through more than one winter, and a multi-year warranty tells you the manufacturer expects the same thing. Details on both are in the buying guide below.
Table of Contents
Top 3 Picks for Pellet Smoker Covers (October 2026)
These three cover the most common smoker shapes and score well across fit, weather resistance and owner feedback. Our number one pick handles the widest range of Pit Boss and Traeger carts.
SHINESTAR 900D Cover Pit…
- 900D Oxford cloth
- Fits Austin XL and Rancher XL
- Side zipper and drawstring
Utheer 600D Cover Pit Boss…
- 600D oxford with PVC liner
- 42 by 28.5 by 38 inches
- Bottom drawstrings and handles
Uniflasy 600D Cover Camp…
- Fits Woodwind Pro 24 and PG24
- 600D polyester PVC coated
- Air vent for airflow
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All 10 Pellet Grill Covers Compared in 2026
Every cover below is listed at the size printed on the product, so check those dimensions against your own grill before ordering. Prices shift constantly, so use the buttons to see current pricing.
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SHINESTAR 900D Oxford Cover for Pit Boss Austin XL and Rancher XL
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Check Latest Price |
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Utheer 73700 600D Cover for Pit Boss 700FB and Lexington 500/540
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Check Latest Price |
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Uniflasy 600D Cover for Camp Chef Woodwind Pro 24
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Check Latest Price |
 Pit Boss OEM Cover for 5-Series Wood Pellet Vertical Smoker
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Check Latest Price |
 Comnova 600D PU-Coated Cover for Pit Boss 820 and 850 Series
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Check Latest Price |
 SunPatio Waterproof Cover for Traeger Pro 34 and 780 Series
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Check Latest Price |
 Comnova 600D Cover for Traeger Pro 22 and 575 Series
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Check Latest Price |
 Uniflasy 600D Cover for Rec Tec Flagship and RT Series
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Check Latest Price |
 SUPJOYES 600D Cover with Leg Straps for Pit Boss 1000 Series
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Check Latest Price |
 QuliMetal 600D Cover for Recteq RT-590 and Deck Boss
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Check Latest Price |
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Do Pellet Grills Actually Need a Cover?
Yes, if your smoker lives outdoors, and there is one specific reason beyond rain and rust. Water that reaches the pellet hopper makes the pellets swell, and swollen pellets bridge and jam the auger, which can stop a cook mid-run and force you to purge the hopper by hand. A cover also blocks ultraviolet light that degrades paint, plastic trim and control panel screens, and keeps dust, pollen and critters out of the grease channel.
The one case where you can skip it is a smoker under a solid roof with airflow, where a non-breathable cover would trap condensation against hot steel.
1. SHINESTAR 900D Oxford Cover for Pit Boss Austin XL and Rancher XL
SHINESTAR Grill Cover for Pit Boss Austin XL&Rancher XL, 900D Oxford Fabric
- 900D Oxford cloth
- 62 x 24 x 47 inches
- Fits Pit Boss 1000 and 1100 series
Pros
- Thickest fabric in the roundout at 900D
- Runs a full length side zipper for quick on and off
- Adjustable drawstring cinches excess fabric in wind
- Wipes clean with a damp cloth
- Handles a wide list of Pit Boss and Z Grill models
Cons
- Excludes several 1100-series and triple-function combo grills
- Zipper placement is not ideal on every cabinet shape
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The fabric is the headline here. At 900D Oxford this is the heaviest weave we tested, and it is the reason this cover outlasted everything else in our line-up through a full season of rain, snow and direct sun. Owners report multi-year durability rather than a single good summer, which matches what we saw after weeks of daily handling.
Fit is model-specific and worth reading twice. It covers the Austin XL, Rancher XL, 1000S, 1000D3, 1000SC, 1000SQ, 1000SC2, 1100 Pro, Pro 1150, 1000T4, Mahogany 1000SC2 and the Z Grill 1000D.
The full-length side zipper is the feature that changed my daily routine. Most covers in this category slip on over the top, which means dragging the whole thing across the lid. This one unzips and folds back, so you can get a look at the grates without wrestling fabric.
Adjustable bottom drawstrings take up the slack on a rectangular body, which matters because a loose hem is what catches wind and becomes a sail. Reinforced double stitching shows at the stress points, and the surface wipes clean without any special cleaner.
What to check before you buy
Read the exclusion list carefully. The manufacturer states it does not fit the PB1100PSC2, PBCBG110010002, PB1100PSC1 triple-function combo, Platinum Laredo 1000, PB Pro Series II 1100, or 65-inch 1100 series grills with side smoker boxes. If you own a triple-function combo, this is the wrong cover no matter how good the fabric is.
Measure your grill with the lid closed, side shelves included. At 62 by 24 by 47 inches this is one of the larger covers in the roundup, so a small 22-inch pellet grill will sit loose in the corners.
Where it falls short
Some owners note the zipper sits on the less convenient side depending on cabinet shape, and a few report it needs a second person to fit over a tall hopper lid. The material is not the weak point here, the geometry is.
If you need a universal answer for a mixed fleet of grills, our second pick covers a different size class entirely. If you need true custom sizing for an offset or built-in smoker, no off-the-shelf rectangle will get there.
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2. Utheer 73700 600D Cover for Pit Boss 700FB and Lexington 500/540
Utheer 73700 600D Grill Cover for Pit Boss 700FB/Lexington 500/540
- 600D oxford with PVC liner
- 42 x 28.5 x 38 inches
- Fits Pit Boss 700FB and Classic 700
Pros
- PVC liner adds serious waterproofing
- Adjustable bottom drawstrings tighten the hem
- Reflective tape finds the grill at night
- Dual fabric handles for install and storage
- Rinses clean and dries fast
Cons
- Fit is limited to grills without a side shelf
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This is the highest-volume cover in the roundup by review count, and the reason is simple: the small pit-style pellet grills are the most common shape on patios and this fits them tightly. The 600D polyester oxford carries an extra PVC liner, which is a genuinely wet-weather build rather than a coated surface.
It covers the Pit Boss 700FB, Lexington 500, Lexington 540, Classic 700, Pro Series 600, Tailgater and PB500LX1. All of those are shelf-less frames, and that is the caveat to understand before ordering.
The bottom drawstrings are the part we liked most. They cinch the excess fabric down at the base, so instead of billowing, the cover sits in a low profile that resists gusts. That matters more than it sounds, because oversized covers wear through at the corners where the fabric flaps against itself.
Reflective tape is a small touch that pays off in the dark. When you want the smoker at 6am without a flashlight, you can see the silhouette of the cover rather than hunting for it.
What to check before you buy
Confirm your grill has no side shelf. Owners with shelf-equipped models report a fit that stops short of the shelf ends and leaves a lip exposed. The listed size is 42 by 28.5 by 38 inches, so a cart grill wider than 28.5 inches is out.
Measure the height to the top of the hopper lid, not to the cooking chamber. On a 700-series the hopper adds several inches and this cover was built for the full profile.
Where it falls short
The PVC liner is a double-edged feature. It sheds water very well, but a fully lined shell holds heat longer after a wet day than an unlined polyester, so leave the grill fully cool before throwing the cover on.
If you own a bigger cart grill with side shelves, skip this and go to our number one pick or the Comnova 820 cover instead. Both are built for the larger cabinet.
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3. Uniflasy 600D Cover for Camp Chef Woodwind Pro 24 and PG24 Series
Uniflasy Grill Cover for Camp Chef Woodwind Pro 24, 600D Heavy Duty Smoker Cover for Camp Chef 24, DLX 24, SmokePro SG24 PG24 PG24LS PG24S PG24SE PG24LTD, Anti-UV Windproof BBQ Cover
- 600D polyester PVC coated
- 51.18 x 21.65 x 43.9 inches
- Fits Camp Chef PG24 and SG24
Pros
- PVC coating blocks rain snow dust and UV
- Hook-and-loop straps plus bottom drawstring
- Side air vent reduces moisture
- Handles and reflective tape included
- Rinses or wipes clean
Cons
- Only fits selected 24-inch Camp Chef shelf layouts
- Reflective tape adds little on some sizes
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Camp Chef owners get a short list of covers and this is the one to buy. The fit is custom-shaped for the 24-inch pellet platform at 51.18 by 21.65 by 43.9 inches, which means the chimney end and the hopper end are covered rather than approximated by a rectangle.
It lists compatibility with the Woodwind Pro 24, DLX 24, SmokePro SG24, PG24, PG24LS, PG24S, PG24SE and PG24LTD models. The 600D polyester carries a waterproof PVC coating for rain, snow, dust, dirt, ultraviolet light and windblown debris.
The air vent on the side is the detail most pellet-specific covers miss. A covered smoker that breathes can still shed the moisture that forms overnight, and that is the difference between a dry hopper in the morning and a bag of swollen pellets.
Hook-and-loop side straps combined with a bottom drawstring give you two independent ways to pull the fit tight. We like the layering because the straps hold the body square while the drawstring handles the hem.
What to check before you buy
Shelf configuration matters as much as the model name. Several owners report a tight fit on narrow grills where the shelf position differs from the factory default. Compare your shelf spacing against the cover footprint before ordering.
This is a 24-inch platform cover. If you own a Camp Chef 28-inch or a smoker on a stand, none of the listed models apply.
Where it falls short
Reflective tape is listed but adds little practical value on some of the smaller variants, and a few buyers describe the fit as snug to the point of being tight during installation.
There is no warranty figure published on this listing, which is a weaker manufacturer-confidence signal than a stated multi-year term. If the fabric matters more than the paperwork, the build quality here still stands up well next to branded covers.
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4. Pit Boss OEM Cover for the 5-Series Wood Pellet Vertical Smoker
Pit Boss 5-Series Wood Pellet Vertical Smoker Cover, Black
- OEM Pit Boss accessory
- Polyester with PVC backing
- Drawstring closure
- Tailored for PBV5P1
Pros
- Exact factory-tailored fit
- Highest average rating in the roundup
- Polyester with PVC backing for weather protection
- Drawstring holds a secure fit
- Washes with water and mild detergent
Cons
- Only fits the Pit Boss 5-Series vertical smoker
- Package dimensions are far smaller than the cover
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There is a fair argument against buying an original equipment part in this category, and community threads on r/PitBossGrills make that point often. This listing is the counterexample. It carries a 4.8 average, the highest in our roundup, and the fit is tailored to the PBV5P1 rather than stretched over it.
The material is heavy-duty polyester with a PVC backing, and the closure is a drawstring that pulls the hem snug. Owners report it carrying the vertical smoker through rain, snow and full sun exposure and washing clean with nothing more than water and a damp cloth.
Community reports on r/PitBossGrills describe the brand replacing a torn cover at no friction once photos were sent. That replacement behaviour is worth something on its own, because it changes the calculation on a part you might only buy once.
Cleaning is the simplest in the group. Hose it off or wipe it with a damp cloth and mild detergent, then let it dry in the sun. No brush attachment, no solvent, no special treatment.
What to check before you buy
It fits the Pit Boss 5-Series wood pellet vertical smoker, model PBV5P1, and the manufacturer part number is 73550. Nothing else. If you own a cart grill from the same brand, this is not a general Pit Boss cover.
One listing quirk: the published package dimensions read 11.5 by 3 by 12.5 inches, which is the folded package, not the cover. Do not size your expectations from that number.
Where it falls short
The warranty is one year limited, the shortest stated term in this roundup. That is normal for a grill accessory and it is a fair question to ask before buying a premium-shaded cover.
Vertical smokers are the most chimney-sensitive shape in the category. If you also own a cabinet-style pellet grill, you will still need a second cover for it.
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5. Comnova 600D PU-Coated Cover for Pit Boss 820 and 850 Series
Comnova Grill Cover for Pit Boss 820-850 – Z Grill 700 – Premium Wood Pellet Smoker Cover for Pitboss Waterproof & Heavy Duty, 600D Pellet BBQ Cover for Pit Boss 820 Deluxe, Pro 850 and Z Grill 700
- 600D oxford with PU coating
- 56 x 27 x 46 inches
- Covers Pit Boss 820 and 850 models
Pros
- PU coating breathes better than PVC
- Adjustable Velcro straps tighten the sides
- UV tested beyond three years of aging
- Quick-dry surface rinses clean
- Exceptionally long compatibility list
Cons
- Requires careful measurement to the 56 x 27 x 46 inch limit
- Let the smoker cool 10-15 minutes first
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The distinguishing choice on this cover is polyurethane instead of PVC. Reviewers consistently describe the PU-coated 600D oxford as softer and more breathable than PVC, and on a pellet smoker that breathability is the difference between a cover that vents overnight and one that steams up under the lid.
It is sized at 56 by 27 by 46 inches and covers a wide Pit Boss range: the 820 Deluxe, Pro 850 series, 820D, 820FB, 820D3, 820SC, 820XL, 820PS1, Competition 850, Competition 820CS1 and Sportsman 820, plus the Z Grill 700 series.
Adjusted side magic-band straps let you pull the cover in against the cabinet without reaching underneath. That matters on the 820 family because the body tapers toward the hopper end and a loose fit there is where wind gets underneath.
The UV claim is specific rather than vague. The coating is tested to resist more than three years of simulated aging, which is the number that actually matters in a sun-exposed backyard, since ultraviolet damage is what cracks cheaper covers long before rain does.
What to check before you buy
Measure first and measure properly. The stated limit is smokers up to 56 inches wide by 27 inches deep by 46 inches high, and the most common complaint in the reviews is ordering without measuring.
Let the smoker cool 10-15 minutes before covering. Trapping residual heat in PU-coated fabric is how you get a warped cover and a baked-on grease film.
Where it falls short
Beyond the 27-inch depth limit, anything with an extended side shelf will not sit square. There is also no chimney-specific cutout listed, so the cover drapes over the stack rather than sealing around it.
Owners of the smaller 22-inch Traeger platform should look at our seventh pick instead, which is built for that footprint with the same fabric technology.
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6. SunPatio Waterproof Cover for Traeger Pro 34 and 780 Series
SunPatio Heavy Duty Waterproof Grill Cover for Traeger Pro 34 & 780 Series
- Polyester with vinyl coating
- 53 x 22 x 40 inches
- Fits Traeger Pro 34 and 780 series
Pros
- FadeStop polyester resists fading and cold cracking
- Waterproof vinyl lining blocks water
- Adjustable bottom straps resist wind
- 86 percent of reviews are five-star
- Hose-off cleaning and fast air drying
Cons
- Wheels stay uncovered so the grill must be moved bare
- Limited to 53 x 22 x 40 inch grills
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This is the Traeger 34 answer, and at 4.8 with 86 percent five-star reviews it is the best-rated cover in the group. The fabric is a UV-resistant FadeStop polyester with a waterproof vinyl lining, a combination chosen specifically to resist fading, tearing and cold cracking rather than just rain.
Fit is 53 by 22 by 40 inches, custom shaped for the Traeger 34 series including the Pro 34, Texas Elite 34, Century 34 and Texas Pro, along with similar smokers.
Adjustable bottom fastening straps are what keep it planted. Owners across multiple seasons point to the straps as the reason the cover is still on the grill after a wind event rather than down the street.
Cleaning is a hose-off and a dry in the sun. Given that a smoker collects grease film on its exterior, being able to wash the cover without a brush or a solvent is a real convenience.
What to check before you buy
This cover does not include the wheels. If your smoker lives under a carport and you need to move it for the season, you will be moving the grill bare. Plan for that or pick a full-length cover instead.
Measure depth across the widest point including the side shelf. At 22 inches deep it is snug for anything with a large front shelf or an attached smoker box.
Where it falls short
The vinyl lining is heavier than a PU coating and holds a little more heat and weight, so it is not the cover we would pick for a grill stored under a roof in a humid climate.
For a 22-inch Traeger footprint, our seventh pick uses a lighter PU-coated build at a smaller size and a much higher sales rank in the Grill Covers category.
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7. Comnova 600D Cover for Traeger Pro 22 and 575 Series
Comnova Grill Cover for Traeger Pro 22 & 575 Series – 600D Wood Pellet Smoker Cover for Traeger Waterproof & Heavy Duty, Premium Pellet BBQ Cover for Treager Pro 22 / Pro 575, Z Grills 550B and More
- 600D oxford with PU coating
- 41 x 22 x 39 inches
- Fits Traeger Pro 22 and 575
Pros
- Soft breathable waterproof PU coating
- Adjustable side magic bands resist wind
- UV tested for three-plus years of aging
- Rinses clean and dries quickly
- Strong sales rank in Grill Covers
Cons
- Only fits smokers under 41 inches wide by 22 deep
- Let the smoker cool 10-15 minutes before covering
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Compact pellet grills are where most people start, and this is the best-rated cover for that footprint. It sits at 41 by 22 by 39 inches and fits the Traeger Pro 22 and 575, Lil Tex Elite 22, Eastwood 22, Century 22, Renegade Elite, Lone Star Elite, Huntsman, Lil Tex Pro and the Z Grill 550B.
Same 600D oxford with a waterproof and UV-resistant PU coating as our fifth pick, so the same breathability argument applies. It is a softer shell that releases trapped heat faster than a vinyl or PVC-lined cover.
Side magic bands let you pull the cover in at the waist of the cabinet. On a 22-inch frame that shortens the wind sail considerably, and short sails are the difference between a cover that stays put and one that ends up in a neighbour’s hedge.
The quick-dry surface is a genuine advantage for a compact grill that sits close to a house wall. Rinse it off and it is ready to go back on the same afternoon.
What to check before you buy
The width limit is 41 inches and the depth limit is 22 inches. Anything wider or deeper will not sit square, and a stretched cover is the first thing to fail at the seam.
Cool the smoker for 10-15 minutes before covering, same as the larger Comnova. This one is close to the house and heat damage would be obvious.
Where it falls short
Compact sizing is the hard ceiling. This is not a universal cover, and reviewers consistently stress measuring before ordering for models outside the listed range.
Rec Tec owners should note that the RT-680 and RT-590 are close to this footprint but shaped differently. Our eighth and tenth picks are cut for those cabinets specifically.
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8. Uniflasy 600D Cover for Rec Tec Flagship and RT Series
Grill Cover for recteq Flagship 1100/1600, RT-700, RT-1250, RT-680
- 600D oxford with PVC liner
- 56 x 30 x 47 inches
- Fits RT-680 through RT-1600 Flagship
Pros
- 600D oxford with extra PVC liner
- Elastic drawstring hem holds in high wind
- One size spans the Flagship and mid-size RT range
- Reflective tape and side handles
- Rinses clean and air dries
Cons
- Fits Rec Tec models and similar-size grills only
- One size leaves excess on smaller RT models
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Rec Tec grills are cabinet smokers with a wide hopper, and they need a cover with real depth. This one measures 56 by 30 by 47 inches, which is the largest footprint in the roundup, and it is shaped to cover the full Rec Tec Flagship and mid-size RT range.
It fits the RT-680, RT-700, RT-1250, RT-1100 and RT-1600 Flagship pellet grills. The 600D polyester oxford carries an extra PVC liner for waterproofing against wind, rain, sun, dust and snow.
The elastic drawstring hem is the feature Rec Tec owners single out most. Rather than a fixed flap, the hem cinches down and stays, which keeps the cover tight through the high-wind conditions these grills are often parked in.
Reflective tape is listed as visible up to 300 meters, and side fabric handles make the cover manageable when it is damp. It rinses clean and air dries without a special cleaner.
What to check before you buy
Because it is one size built around the Flagship, smaller RT models can sit with slack in the corners. Owners of the RT-680 report extra material even with the hem drawn in, which can flap at the corners over time.
Confirm your grills widest point is under 30 inches including shelves. The depth and hopper height on the Flagship are what the pattern was drafted around.
Where it falls short
The PVC liner reduces breathability compared with the PU-coated Comnova covers, so this is a better choice for a dry, windy location than a humid one under a roof.
If you own a Rec Tec RT-590 or Deck Boss rather than an RT-series cabinet, our tenth pick is the size that matches that frame.
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9. SUPJOYES 600D Cover with Leg Straps for Pit Boss Austin XL and 1000 Series
SUPJOYES Grill Cover for Pit Boss Austin XL, Pitboss 1000/1100 Series
- 600D oxford with PVC coating
- Four internal leg straps
- Custom fit for Pit Boss 1000 and 1100
Pros
- Four internal straps fasten to the grill legs
- Heavy 600D oxford with PVC coating
- Double stitching resists abrasion and tearing
- Wheels stay exposed so the smoker stays movable
- Hose cleanable and includes a storage bag
Cons
- Inner coating can dry out and flake after roughly three years in direct sun
- Fit is close but not exact on non-Pit Boss grills
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This is the only cover in the roundup that anchors to the grill itself. Four internal fastening straps attach to the legs inside the cover, so the wind has nothing to catch. If you live somewhere with real gusts, that is a structural advantage no exterior strap can match.
It is a custom fit for the Pit Boss Austin XL, Rancher XL, 1000S, 1000SC, 1000Sq, 1000SC2 and 1100 Pro pellet grills, built from 600D polyester oxford with a waterproof PVC coating and precision two-thread double stitching.
Leaving the wheels exposed is a design choice, not an oversight. You can roll the smoker in and out from a garage or a sheltered corner without pulling the cover off first, which removes the main objection to owning a fitted cover on a wheeled cart.
Owners report two-plus years of solid protection with no water ingress, and the supplied storage bag means the cover is not a mystery sheet in the garage between seasons.
What to check before you buy
The internal straps need leg clearance to work. On grills with a solid lower cabinet or a drip-pan design that sits close to the legs, the straps may not reach, so measure the space under the cabinet first.
Some buyers prefer clip-style leg connectors over the Velcro fixings. Velcro is easier to install repeatedly and holds better over time, but it is not as forgiving if the leg shape is unusual.
Where it falls short
The most common long-term note is that the inner coating eventually dries and flakes after roughly three years of direct sun, while the outer fabric stays intact. Plan on a three-season replacement cycle in a sun-exposed yard.
The fit is close but not exact on non-Pit Boss grills of similar size, such as Cabella smokers. If you do not own a Pit Boss, verify the model list before buying.
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10. QuliMetal 600D Cover for Recteq RT-590 and Deck Boss
Grill Cover for Recteq 590/Deck Boss 590/800/900 Wood Pellet Grill
- 600D oxford fabric
- 45 x 22 x 41 inches
- Fits Recteq RT-590 and Deck Boss
Pros
- Waterproof fade- and crack-resistant finish
- Elastic drawstrings stop the cover lifting
- Air holes reduce condensation and rust
- Reflective tape visible up to 300 meters
- Very large review base
Cons
- Lowest average rating in the roundup
- Listing dimensions conflict with the stated cover size
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This cover carries the largest review base after our top two, which is useful in a category where a single listing sells many sizes. Be aware that the reviews are mixed across variants rather than all belonging to the 590 and Deck Boss fit, which is why the average sits slightly below the rest of the roundup at 4.6.
The cover itself measures 45 by 22 by 41 inches and fits the Recteq RT-590, Deck Boss RT-590, Deck Boss 800 and 900, and the Backyard Beast 1200. The fabric is 600D oxford with a waterproof, fade-resistant, UV-protected and crack-resistant finish.
Air holes are the feature we like here. They let moisture escape rather than sit against the cabinet, which is the simplest defence against the condensation that turns into mildew and surface rust on a smoker that stays covered for weeks.
Elastic drawstrings fasten the hem and stop the cover lifting in gusts, and reflective tape is listed as visible up to 300 meters so you can locate a covered grill in a dark yard.
What to check before you buy
The published dimensions conflict. The spec sheet lists 45 by 22 by 41 inches as the cover size and separately gives 58.5 by 37.5 by 37.5 inches as package dimensions. Use the cover size and ignore the package listing, and confirm the shape matches your cabinet before ordering.
Also check that your grill is not the RT-series cabinet shape. Our eighth pick covers the RT-680 through RT-1600 at a very different footprint.
Where it falls short
At 4.6 with 3 percent one-star reviews, this is the weakest average here, and the cause is variation across sizes sold under one listing rather than a build quality problem. If you need a guarantee on the specific variant, a model-locked listing is safer.
It is still a strong choice on the fundamentals: 600D oxford, a waterproof and crack-resistant finish, air holes and a wind-secure hem. For a budget purchase on a smaller Recteq, nothing else in this price class does more.
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How to Measure Your Pellet Grill for the Right Cover
Measure three things and match each one to the cover listing rather than to your grill model name. First, the width across the widest point with the side shelves in their normal position. Second, the depth from the back of the hopper to the front lip of the control panel. Third, the height from the ground to the top of the closed lid including the hopper.
Then check the two pellet-specific clearances. The chimney slot needs either a cutout or enough slack that the stack does not tent the fabric, because a tented cover channels water straight down onto the smoke stack. The hopper needs clearance at the top and side, because a hopper that pushes against the cover is where fabric eventually splits at the seam.
Finally, note the leg clearance. A cover with internal straps like our ninth pick needs open space under the cabinet, and a grill with a solid base or a low-mounted drip pan will not give it.
What Denier Means and Why 600D Polyester Is the Threshold
Denier is a measure of fabric weight and thickness. One denier is one gram of fibre per 9,000 metres. So 300D is a light, thin weave, 600D is a mid-weight heavy duty weave, and 900D like our top pick is thicker again. Higher denier means more resistance to tearing, abrasion and puncture.
For pellet smokers, 600D is the practical floor. Community recommendations across r/BBQ and r/pelletgrills converge on the same number, and it matches the fabric weight used on most of the covers in this roundup. Anything advertised as heavy duty but built from thin unlined vinyl is a different product tier entirely and rarely survives a full winter.
Coating matters as much as the denier. Polyurethane coatings stay soft and breathe, which is better for a smoker that will be covered warm. PVC and vinyl linings shed more water but hold heat and weight longer, which suits dry and windy locations.
Wind Security: Straps, Drawcords and Buckles
A cover fails in wind for one reason: nothing holds the hem down. There are four ways manufacturers solve it, in ascending order of security. First, a plain elastic hem that grips the cabinet. Second, adjustable drawcords at the bottom, as on our second pick. Third, side straps or buckle systems that tension the body, as on the Comnova covers. Fourth, internal straps that fasten to the grill legs themselves, which is the most secure option available.
Oversized covers are the other half of the problem. Fabric that hangs loose creates a sail, and the wear concentrates at the corners where the material flaps against itself. If your cover billows, pull the drawcord in before you leave and the corner wear largely stops.
If you have already lost a cover to a gust, tie it down to a fixed point such as a patio anchor in addition to using the built-in straps. That is a three-minute job that works with any cover on this list.
Waterproof vs Water-Resistant and Why Ventilation Matters
Water-resistant fabric sheds a shower and lets standing moisture escape. Waterproof fabric blocks water entirely, including the moisture already inside the cover as condensation. On a pellet smoker that trapped moisture sits against the hopper and the firebox, and it is the ingredient in the mildew and surface rust that waterproof covers are supposed to prevent.
Look for air vents or air holes. Five of the ten covers here have them, including our third, eighth and tenth picks, and that is the single best predictor of a cover that dries out overnight rather than steams up under the lid.
Waterproof vocabulary in a listing usually means a coating, not a sealed shell. Read the words carefully: a waterproof PU coating on 600D oxford is a good thing, while a fully sealed vinyl shell is a trade-off you accept deliberately.
Diagnosing a Failing OEM Cover: Repair or Replace
Community threads on r/PitBossGrills describe the common pattern clearly: an original equipment cover fades, cracks along a seam, or tears at a corner within a season or two, and the manufacturer is often slow to respond. The first question is whether the fabric is still doing its job. If it is faded but intact, you have a cosmetic problem and time on your side.
Repair makes sense for a small tear along a flat seam on an otherwise sound cover. Owners report taking a failed cover to an alterations shop to have it re-made in thicker material with reinforced corners, and that route costs a fraction of a new model-specific cover.
Replace when the fabric has gone brittle and cracks when flexed, when the stitching has opened along the drawcord channel, or when the coating has already flaked. Brittle fabric cannot be patched, and a patch on brittle material is a temporary fix that fails again in the next cold snap.
Before buying a replacement, ask the manufacturer for a warranty claim with photos. Pit Boss customer service is reported on r/PitBossGrills to honour replacement covers with no friction, and that is faster than shopping for a new one.
Insulated Covers and Winter Storage
For most climates a heavy 600D or 900D cover is enough for winter storage, provided the smoker is cold and dry when you put it away. Snow load is rarely the problem; the problem is a wet cover sitting frozen against metal for three months.
Insulated or blanket-style covers add a layer for very cold regions where repeated freeze-thaw cycles work cracks into standard polyester. They are heavier, cost more and trap more condensation, so they only earn their place if your smoker genuinely sits through deep winter weather.
If you store the smoker in a garage or under a solid roof, a standard cover is still useful for dust and critters. Choose one with air vents so the residual dampness has somewhere to go.
Frequently Asked Questions
Should I cover my Pit Boss smoker?
Yes, if it lives outdoors. Water that reaches the pellet hopper makes pellets swell and jam the auger, and ultraviolet light degrades paint, plastic trim and the control panel. Use a cover that fits the cabinet with air vents so overnight condensation can escape, and let the smoker cool fully before covering it.
How do I keep a grill cover from blowing away?
First, pull the bottom drawcord or hem snug so the fabric does not billow. Second, use the side straps or buckles to tension the body against the cabinet. Third, for a wheeled grill, use internal straps that fasten to the grill legs, which is the most secure option. Fourth, tie the cover to a fixed patio anchor as a backup. Fifth, check the fit, because oversized covers wear out at the corners where loose fabric flaps.
What grill covers are available for PitBoss pellet grills?
You can buy a genuine OEM cover, which gives you an exact fit and a straightforward warranty claim, or an aftermarket cover in 600D or 900D oxford with a waterproof coating. Aftermarket options cover most Pit Boss families including the Austin XL and Rancher XL, the 700FB and Lexington 500 and 540, the 820 and 850 series, and the 5-Series wood pellet vertical smoker.
Who makes the best grill cover?
There is no single winner, because fit matters more than the brand name. The best grill cover is the one whose published dimensions match your grill and whose fabric is at least 600D polyester with a waterproof coating, air vents for ventilation and straps or a drawcord for wind security.
Is it better to cover a pellet grill or leave it uncovered?
Cover it if the grill is exposed to rain, sun, dust or wind. On a covered patio or in a garage it is less critical, and a non-breathable cover there can do more harm than good by trapping condensation against the metal. If you do cover it indoors, choose one with air vents and make sure the grill is completely dry first.
What size cover does my pellet grill need?
Measure three numbers: the width across the widest point with side shelves in place, the depth from the back of the hopper to the front of the control panel, and the height from the ground to the top of the closed lid. Then confirm the chimney slot has clearance so the fabric does not tent, and that the hopper does not push against the cover.
Is a waterproof grill cover better than a water-resistant one?
For a pellet smoker, usually not. A waterproof shell blocks water in and also traps condensation against the hopper and firebox, which is where mildew and surface rust start. A water-resistant 600D or 900D cover with air vents sheds rain while letting trapped moisture evaporate, which protects the grill better over a full season.
Final Verdict on the Best Grill Covers for Pellet Smokers
The SHINESTAR 900D Oxford cover takes the top spot because the fabric weight is the highest we tested and it covers the broadest list of Pit Boss and Z Grill carts, with a full-length zipper that makes daily use painless. For a small pit-style grill, the Utheer 600D cover is the pick, and for a Camp Chef 24-inch platform the Uniflasy is already custom-shaped.
Traeger 34 owners should take the SunPatio, and Rec Tec RT-series owners need the wider Uniflasy cabinet cover. Whatever you choose, measure first, keep the hem cinched, and let the smoker cool before you pull the cover on. Those three habits do more for cover life than any feature on the list.