Char-Griller Modifications


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Here are some links and photos of modifications you can make to your
pit to make it more efficient. These are based on the

  Char-Griller Side Fire Box
Char-Griller Smokin' Pro with the Side Fire Box
If you already have the Char-Griller Smokin' Pro you can purchase the Side Fire Box separately. Your best bet is to purchase them together.

HomeBBQ Smoker Modification Knowledge base document (pdf)
bbq-ext-them1.jpg (72209 bytes)bbq-ext-them2.jpg (48347 bytes)Get some small thermometers from Lowes or Home Depot BBQ or use this link for a great smoker thermometer, and set them at either end of the body of the grill just below the lid level. There are holes predrilled at the right location. I found some perfect ones that allow the probe to pass through the hole and a threaded shaft and nut placed just right for attachment. You can easily monitor the interior temperature at the grill level on both sides.
 
bbq-int-pipe.jpg (71405 bytes)The top vent in the Char-Griller lets out all the hot air. Hot air rises so you need to lower the vent pipe to at least the grill level. Get some 3" semi-rigid dryer vent pipe. Slip the vent over the internal projection of the vent pipe and form the vent to the outside of the top cover. I cut off the vent pipe at the right level so the edge wedges against the inside lip of the lid. I took the top warming rack out as I rarely use it. This has held securely without any clamps or drilling. You'll see an improvement in consistent temperatures and lower your fuel consumption.

bbq-ext-pipe.jpg (68986 bytes)You can use the leftover piece of vent pipe to extend the top pipe as well. Putting a curve in it allows you to direct the smoke away from you and better control the temperature.

 

Another option would be to drill and cut a hole in the side opposite the firebox below the grill level and attach vent pipe running up from there. You'll have to stabilize the vent pipe well as it has nothing to attach to above the lower section.
Some people recommend turning the charcoal tray over in the main body of the pit, and let it act as a baffle. I have not seen a big difference when doing this, but I'll try it a few more time. (still no difference) I've cut a piece of sheet metal to rest just above the firebox opening in the main body of the pit. I bent one edge to provide some rigidity. I then drilled a series of holes in a triangle pattern increasing in quantity as you go further from the firebox. This allows more air to flow through as you go further from the box. It deflects much of the heat towards the middle and avoids a strong hotspot at the opening. It remains to be seen how effective this is. (I've removed it as it didn't help much)
I have had good luck with lining the inside of the lower section with heavy foil and adding two bricks set on their side with a foil drip pan. This does several things. Reflects the heat back from the lower area. Makes for easy cleanup. The bricks retain heat and keep the interior more stable (I've heard of adding ceramic briquettes for the same purpose). The drip pan sits up a bit higher and acts as a baffle.
Use some sort of charcoal basket in the firebox. I've seen people make them of a variety of materials. I've tried a couple different options and they work very well. It keeps the coals more closely grouped and hot and makes it easier to slide out the tray below to empty the ash on a long cooking session.

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