Hi there and welcome!
I'm always in the "go with a PID controller" camp lol. Why?
Because your smoker will now be able to smoke ANYTHING because of the tight control and the accuracy you can achieve with your temps.
This means bacon, jerky, sausage, etc. no temp swings to ruin it.
If your insulation can handle smoker temps at 325F for 4 hours max or so, this means you can now do skin on chicken and turkeys where they will have easily edible skin and very likely even crispy skin!!!
So my suggestion is get a PID controller and do a simple where the existing cord hooks directly to the heating element or you take the existing wiring that goes to the existing controller and splice around the controller to where the wiring runs to the heating element.
This would make the cord and the smoker dumb where when it is fed electricity it will go directly to the heating element and heat up WITHOUT any control.
A PID controller will run you $150 but really what you are buying is a whole new smoker for $150, not a part for a smoker.
With a replacement thermostat costing $50, you will really only bet getting a "new" improved smoker for $100 difference!
Just for clarity this would work in the following way:
- Rewired smoker cord plugs into the PID controller
- PID controller temp probe drops down the smoker vent and you clip it to the bottom of the lowest rack, on the underside of the rack, in the center of the rack to read the smoker temps
- Plug the PID into the wall outlet and punch in the smoker temp you want
- The PID will take power from the wall outlet and feed it to the smoker to hit and hold at the set temp you entered into the PID
- It will hold dead on or within 1-3 degrees of your set temp
- Done!
That is too good of a smoker to throw out and I believe you would be drastically improving upon an already good thing if you went the PID controller route.
Just my 2 cents. I hope this info helps :D