More Surface, Same Control, Heavier Build — The Broil King Regal Pellet 500
A heavy-duty Wi-Fi and Bluetooth pellet smoker and grill with 625 sq. in. of primary cooking space, 200 sq. in. secondary, cast iron grids, a 22-lb hopper, deluxe rotisserie kit, and two electronic meat probes included.
The Broil King Regal Pellet 500 is the larger sibling of the Regal Pellet 400 — same 2mm (14 gauge) steel body, same Wi-Fi and Bluetooth digital controller, same heavy-duty cast iron cooking grids and ash management system — but with 625 square inches of primary cooking surface and 200 square inches of secondary surface for buyers who regularly cook for larger groups or want more room to run multiple proteins simultaneously. The 22-lb hopper handles long cooks, the deluxe rotisserie kit and two electronic meat probes come in the box, and the removable grease management system keeps cleanup manageable. If you've identified the Regal Pellet 400 as the right platform but need more cooking real estate, this is the direct step up.
Why Step Up to the Regal Pellet 500
Six things that define this platform — and the one key difference from the 400.
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625
Sq. In. Primary Surface
125 sq. in. more primary surface than the Regal Pellet 400 — room for a full brisket and ribs at the same time.
200
Sq. In. Secondary Surface
70 sq. in. more secondary surface than the 400 — meaningful extra capacity for holding, warming, and staging during longer cooks.
2mm
Steel Body (14 Gauge)
Same heavy-gauge steel construction as the Regal Pellet 400 — better heat retention and durability than lighter pellet units.
Wi-Fi
+ Bluetooth Control
Digital controller with remote monitoring — adjust temperature from inside during those eight-hour smoke sessions.
22 lb
Pellet Hopper
Same hopper size as the 400 — plan for more frequent refills when running the larger cook surface at higher temperatures for extended sessions.
2 Probes
+ Rotisserie Included
Deluxe rotisserie kit and two electronic meat probes in the box — ready to cook from multiple angles on day one.
What's Included in the Box
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Grill & Cooking System
- 2mm (14 gauge) steel grill body
- Heavy-duty cast iron cooking grids
- Wi-Fi and Bluetooth enabled digital controller
- 22-lb pellet hopper with auger system
- Removable grease management system
- Unique ash management system
Included Accessories
- Deluxe rotisserie kit
- 2 electronic meat probes
Storage & Convenience
Fuel
- Wood pellets (sold separately — not a gas grill)
Deep Dive — Regal Pellet 500
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Heavy-duty steel construction for serious pellet grilling
The Regal Pellet 500 grill body is built from 2 mm steel for a more substantial and durable feel than many lighter pellet units. That heavier construction helps support better heat retention and long-term outdoor durability, making it a strong option for buyers who want a pellet grill that feels more robust right out of the box.
WiFi and Bluetooth control for smarter temperature management
The digital controller is designed to make temperature monitoring and adjustment easier while smoking, roasting, or searing. With WiFi and Bluetooth connectivity, the Regal Pellet 500 offers a more modern pellet-cooking experience for buyers who want greater control and easier monitoring during longer cooks.
Wood-fired versatility with expanded cooking capacity
With 625 square inches of primary cooking space and 200 square inches of secondary cooking space, the Regal Pellet 500 offers strong capacity for everyday meals, longer smoking sessions, and backyard entertaining. Heavy-duty cast iron cooking grids and the included deluxe rotisserie kit expand its versatility well beyond basic pellet smoking.
Smart cleanup and storage features for easier backyard use
The Regal Pellet 500 includes a removable grease management system, a unique ash management system, base storage, and a side shelf to support a cleaner and more functional outdoor workflow. For buyers building a more capable outdoor cooking setup, these features help make pellet grilling more convenient day to day.
Who It's For — The Deck & Den Take
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The Regal Pellet 500 is for the buyer who looked at the 400 and thought "I need more room." If you regularly cook for eight or more people, or you want to run a full brisket and a rack of ribs at the same time without staging them in rotation, the extra 125 square inches of primary surface is genuinely useful — not just a number on a spec sheet.
One thing worth knowing before you order: the hopper is the same 22 lbs. as the 400, but you're heating a larger chamber. At lower smoking temperatures that's usually fine, but at higher heat settings or during longer cooks you'll burn through pellets faster than the 400 would. Keep extra bags on hand.
If you're deciding between the 400 and 500 and you're unsure: the 400 is the better everyday grill for most households. The 500 earns its size and weight (250 lbs. vs. 220 lbs.) for buyers who specifically need that additional capacity on a regular basis.
- Buyers who regularly cook for larger groups and need more primary surface than the Regal Pellet 400 provides
- Cooks who want to run multiple large proteins — brisket, pork shoulder, ribs — simultaneously without staging
- Buyers who've already identified the Regal Pellet platform as the right choice and need the step-up size
- Shoppers who want Wi-Fi monitoring, cast iron grids, and rotisserie capability in a larger-format pellet grill
Full Specifications & Dimensions
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General
| Brand |
Broil King |
| Model |
Regal Pellet 500 Smoker and Grill |
| Collection |
Pellet Grills |
| Model Number |
496051 |
| Fuel Type |
Wood pellets (not a gas grill) |
Construction
| Body Material |
2 mm (14 gauge) steel |
| Cooking Grids |
Heavy-duty cast iron cooking grids |
Cooking Surface
| Primary Cooking Surface |
625 sq. in. |
| Secondary Cooking Surface |
200 sq. in. |
| Total Cooking Surface |
865 sq. in. total cooking space including the porcelain-coated warming rack |
Controller & Connectivity
| Controller |
Wi-Fi and Bluetooth enabled digital controller |
| Temperature Range |
Smoke preset: 225°F; Roast preset: 350°F; Grill preset: 600°F. The official manual does not state a separate minimum operating temperature. |
Pellet System
| Pellet Hopper Capacity |
22 lbs. |
| Ash Management |
Unique ash management system |
| Grease Management |
Removable grease management system |
Accessories & Storage
| Included Accessories |
Deluxe rotisserie kit; 2 electronic meat probes |
| Storage |
Base storage and side shelf |
Dimensions & Weight
| Assembled Height |
49.81 in. |
| Assembled Width |
58.75 in. |
| Assembled Depth |
27.5 in. |
| Weight |
250 lbs. (113.398 kg) |
Warranty, Shipping & Returns
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Warranty: 5 years on the high-heat-coated cookbox, 3 years on the cast iron cooking grids, 3 years on the digital controller and components, and 3 years on remaining parts and paint. Warranty is covered and honored directly by Broil King.
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Free Shipping: This item ships free to the contiguous U.S. See our shipping policy.
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Returns: We want you to love it. View our return policy.
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Price Match: Found it for less? We'll match it. Learn about our price match guarantee.
Manuals & Documents
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Frequently Asked Questions
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How does the Regal Pellet 500 compare to the Regal Pellet 400?›
The 500 has 625 sq. in. of primary cooking surface vs. 500 sq. in. on the 400, and 200 sq. in. of secondary surface vs. 130 sq. in. The assembled width is wider at 58.75 in. vs. 52.38 in., and the unit weighs 250 lbs. vs. 220 lbs. Both share the same 2mm steel body, Wi-Fi digital controller, 22-lb hopper, cast iron grids, rotisserie kit, meat probes, and ash/grease management systems.
What type of fuel does the Regal Pellet 500 use?›
The Regal Pellet 500 runs on wood pellets — it is not a gas or propane grill. Pellets are sold separately and are available in a wide range of wood types (hickory, apple, mesquite, cherry, etc.).
What is the primary cooking area of the Regal Pellet 500?›
The primary cooking surface is 625 sq. in., with 200 sq. in. of secondary cooking surface — 825 sq. in. total combined.
What temperature range does the Regal Pellet 500 reach?›
The official manual lists three preset temperatures: Smoke at 225°F, Roast at 350°F, and Grill at 600°F. It does not publish a separate minimum operating temperature.
Is the rotisserie kit included?›
Yes. The deluxe rotisserie kit and two electronic meat probes are both included with the Regal Pellet 500.
Will the 22-lb hopper last through a long smoke on the 500?›
The 500's 22-lb hopper is the same size as the 400's, but it's heating a larger cooking chamber. At low smoking temperatures (180–225°F) consumption is typically 1–2 lbs. per hour, which gets you 10–22 hours from a full load. At higher temperatures or during aggressive cooks, you'll burn through pellets faster than the 400 would. Keep extra bags accessible for long sessions.
What are the assembled dimensions of the Regal Pellet 500?›
The assembled dimensions are: Height 49.81 in., Width 58.75 in., Depth 27.5 in.
Does the Regal Pellet 500 ship free?›
Yes — the Regal Pellet 500 ships free to the contiguous U.S. At 250 lbs. it ships via freight carrier. Contact us with any questions about delivery or setup.
