How to Bypass the Analog Controller

5/16 drill bit size for the probe. I drilled a hole beside where the power cord goes out the bottom to route the wire, couldn't figure out how to get it to go out the same hole as the power cord. Tony, after opening the smoker I figured out why I had such a variance on temps, my maverick probe I just stuck down the hole and it went down and was resting on the smoke box, lol.
 
Sometimes the simple solutions evade us, Mike!  Just like not thinking of running the permanent probe wire out the power cord hole!! :o
 
I wasn't sure how to get the grommet out and didn't want to break it so just made a second hole, its on the bottom so its not visible.
 
You need(ed) to squeeze the cord holder a bit, turn it @180 degrees, then slide it up into the box. It then pulls apart and you can slide the probe around the back and squeeze it back together. I'm still auto tuning mine and it is taking some time. The directions need to be rewritten.
 
Big Fish said:
You need(ed) to squeeze the cord holder a bit, turn it @180 degrees, then slide it up into the box. It then pulls apart and you can slide the probe around the back and squeeze it back together. I'm still auto tuning mine and it is taking some time. The directions need to be rewritten.

I suggest reading the directions again.  The only correction that needs to be made is that it will read box temp when it starts, not 140.  Other than that, the instructions are correct.  I've performed autotunes several times.
 
I had 3 people read it, one is a writter. Sorry, it didn't do what the instructions said. Someone else here had the issue with it.

e. Press SET again 4 more times, until the initial set temperature displays in the
left window (should be 140).

Nope, it said 80, so did someone else's here.

Once the autotune is complete, we recommend writing down the P, I and D settings.  To
retrieve these settings, go back into the PID setting menu the same way you did in step
3a above.

If you go back to 3a, you begin the tuning process all over again.
 
For those that follow, auto parts store and ACE Hardware carry a male X male splice connector that has a plastic sleeve over the spades.  It makes the bridge in one piece vs. multiple parts. 
 
I installed the permanent probe and the controller bypass this past weekend.  I included my process and some photos on the probe installation under the appropriate category "How to install a permanent Auber temperature probe".  Below is information on bypassing the controller.
I chose to install a switch so that I could go back to the stock analog controller should I have an issue with the Auber or one of its probes.
First, I purchased a common DPDT panel mount 2-position toggle switch with screw terminals, rated for 15A, from Amazon.  Below is the link to the switch that I bought.  I like the screw terminals because it allowed me to use crimp-on terminals on the various wires so that I could easily remove them later if needed.  Also, as you can see in the photo below, I found that by removing the screws in the center terminals, the spade terminal that came on the smoker would slip on the switch terminal without having to re-terminate it.  Be sure and check the switch terminals (I did this with a common volt-ohm meter) before installing the wiring to make sure which terminals are "closed" and which are "open" when the switch is thrown in each position.  On the switch I bought, I found that when the switch was thrown in one direction, the terminals on the opposite end of the switch were the ones that were actually "closed".  (As you can see from the wiring diagram below, the terminals in the center of the switch connect to the heating element of the smoker.  When the switch is thrown one way, the heating element is connected to the stock SI controller.  When the switch is thrown the other way, the heating element is connected to the jumper and is controlled by the Auber.)

http://smile.amazon.com/gp/product/B00K858QG2/ref=oh_aui_detailpage_o04_s00?ie=UTF8&psc=1

Like others have posted, I decided to mount the switch in the top of the smoker near the right rear corner at the right edge of the label.  I like the location now (sorry I didn't take a picture), but drilling in that location was a bear.  The sheet metal and label together are every bit of 1/8" thick or more.  The diameter of the switch is 1/2", so I drilled a small pilot hole, then a little larger hole and then finally the 1/2" hole.  Let the drill turn slowly and be patient because the stainless is very hard.  I used cutting oil to help cool the bits.  Regular motor oil will work almost as well.
I made up all of the jumpers and terminated all of the wiring before installing the switch so that it would be easier to access the terminal screws on the switch.  Make sure that you use 14 AWG wire or larger for all conductors.  I used stranded wire since it is easier to work with.  I found that I had to lengthen the wire that goes to the power indicator light due to my switch location (this wire does not need to be 14 AWG).  I then installed the switch with the threaded lock nut provided (see photo).  I installed my switch so that when thrown to the left (looking at the top of the smoker from the front) the standard SI controller was connected and when thrown to the right, the Auber was in control.  I have made up some labels and once I have installed them, I will take a photo and update this post.
I drew up a crude wiring diagram and taped it to the inside of the back panel of the smoker (see photo) so that it would be handy should I have to work on something in the middle of a smoke (which I did on my first smoke, as detailed below).
Before re-installing the back of the smoker, I tested it with and without the Auber to make sure that my wiring was correct.

During my first smoke, I found that the heating element would turn off about 45 minutes into the smoke.  After much stress, I found that I could wiggle the power cord and the element would come back on (as evidenced by the light on the top of the smoker).  About 45 minutes later, the element would stop working again.  Each time this happened, I could wiggle the cord and get it to come back on.  Finally, I decided to take the back off the smoker and troubleshoot the problem.  As it turned out, the crimp-on connector on the heating element conductor that connects to a spade connector on the power cord (the one that comes from the factory encased in shrink tube) was loose.  I cut off the shrink tube from both power conductors and re-terminated all of the conductors with new crimp-on connectors and wrapped well with electrical tape.  The rest of the smoke was flawless.
The moral of the story is that if you are doing the mod above and have the back of the smoker off, go ahead and cut off that factory installed shrink tube and re-terminate the conductors and then reinstall more shrink tube.  It may save you some headaches down the road.
P.S. - You can buy a fairly inexpensive terminal crimp kit from Lowes or other stores that comes with a selection of crimp-on terminals and the stripper/crimper.  This is a handy thing to have around the house because a lot of appliances, etc. use them.  Below is a link to one that I found on Amazon.

http://www.amazon.com/Neiko-50413A-Solderless-Connection-Stripping/dp/B000K7GRCI/ref=sr_1_1?s=hi&ie=UTF8&qid=1419354945&sr=1-1&keywords=terminal+crimp+kit
 

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Just finished.  Ravel, Polish, WIK & Divot, thanks for the info.  It is a simple fix once all the parts are gathered.  The only thing I can add would be a parts list......

1    1/2" titanium drill bit (used for the toggle switch hole)

1    DPDT, 6 prong, on / on, 15A or 20A, toggle switch (link in CUTiger post above)

1    Missile Switch Cover (I ordered it from Electronics123.com item# COM09278)

2    1' long 14awg jumpers (connect from middle of toggle to the temperature dial)

1    6" long 14awg jumper (for one end of the toggle switch, this is the bypass)

1    1' long 16awg jumper (the wire coming from the light indicator must be cut in half &
        this extends it so it can reach the location of the toggle switch)

Spade connectors can be used for everything (except the 16awg extension) even on the toggle as long as the shoulders at the tip of the spade are removed. 
 
I finally got around to posting pictures of the labels that I applied to the by-pass switch on the SI#2 and to the back and top of my Auber.
 
Has anyone tried using 135 degree drill bit for drilling the stainless steel? If so, did it seem to work any better?
 
Thought I'd share an observation. I'm going to do the analog controller bypass and have been reading all the posts about this topic.  I noticed in the photos that CUTiger80 posted that it appears that the spade connectors and wiring that were on the stock controller are high temperature wire and connectors. THHN wire is spec at 194 F. Might be a good idea to go to the local appliance parts supply store or somewhere similar and get a couple feet of high temp wire and 4 high temp connectors
 
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