The first smoker I used was a Brinkmann. I’ve gone through a couple other similar smokers since, each with its own challenges. I suppose if I combined the cost of those smokers I’d come close to what a premium unit might cost. But I’m cheap and hard headed. Sometimes it takes awhile for things to sink in.
I’ve been using a Char-griller Pro for a while now and I’m determined to make it work. With some trail and error, and a lot of fire tending I think I’ve settled on a setup that works.
Char-Griller
Even temperature in a horizontal cooker is a challenge. With the firebox on one side pouring heat into the cook chamber, the temperature on the other side of the cooker can be different by 10’s of degrees. This limits the usable area of the cooker. Baffles are used sometimes to even out the heat. A baffle is basically a steel plate with holes that gradually get bigger away from the firebox. This moves more heat down the chamber, evening out the temperature.
Keeping in mind that I’m a creatively frugal person, I bought a piece of steel plate, drilled holes and placed it in the bottom of the cooker. It sort of worked, but not really. So I gave up on that idea. Then I read a smoker mod blog that described several modifications that included a roasting pan and cookie sheets as a solution for heat distribution and a modified vegetable grill basket to hold charcoal. The roasting pan set up worked, sending hot air and smoke down the chamber. But the pan seemed too thin to effectively distribute heat. The basket idea, however, really worked.
So for heat distribution the steel plate and the roasting pan didn’t work. What eventually did work came with the Char-Griller. It was the charcoal pan that’s used under the main cooking grill. The pan has two detachable handles used to raise and lower the pan. Its not very useful unless you plan to grill something on the main grill. As a smoker yours is probably lying around somewhere.
Charcoal pan for grilling
This pan is a perfect baffle. Its heavy metal, the right length and curved so there’s a lot of space under it for air flow. The curve also matches the curve of the opening between the cook chamber and the firebox. Just flip it over and jam it up against the side of the chamber next to the firebox.
Wind break
Before going any further I want to point out the wind break set up. The wind break in the picture above is behind the ladder. Although it would seem to be a matter of common sense, I’ve only recently begun using a wind break. The temperature in the cooker is affected by what happens outside. If wind is blowing against one side of the cooker the temperature will be lower on that side especially if the cooker is not very tight. By reducing the amount of wind blowing up against the cooker the temperature difference inside is greatly reduced. Its pretty amazing how big a difference this makes.
Okay, so you’ve flipped the pan and jammed it up against the side of the cooking chamber.
Jammed next to firebox
There’s going to be a gap that opens to the firebox. The gap can be stuffed with foil to prevent uncontrolled heat from flowing into the chamber. The heat will flow under the baffling, releasing some of its energy and the rest of the heat out the far side of the chamber. Hot air and smoke is drawn back across the chamber and up into the exit vent that has been redirected with 3 inch flex ducting. One of these days I’ll cut a new hole and move the chimney vent making for more room in the chamber. A project for another day.
Foil in gap near firebox
For easy cleanup, I usually cover the inside of the chamber with foil. I use two large pieces of heavy duty foil and fold the long edges together to form a seam then cover the bottom with it. You can just make out the seam running down the middle of the chamber. I’ve left a gap in the foil cover on the left side of the chamber for heat and smoke to raise up from under the baffling.
Easy cleanup
I use the two probes of a Maverick thermometer to monitor temperature. The smoker probe is used on the firebox side by passing it through a hole in the chamber wall.
Through side of chamber
Then the probe is clipped under the grill.
Clipped under grill
On the other side of the chamber the meat probe also passes through the chamber wall.
Through the side
The probe then pierces a folded piece of foil hanging from the grill suspending it parallel to the surface of the grill.
Hanging on foil
Conditions in the cooking chamber are important and the fire that heats the chamber is equally important. I’ve spend a lot of time tending fires that either grow too hot or too cold, too quickly. I’ve tried the Minion method with varying success since the Brinkmann. I use a kind of horizontal Minion in this setup, its a horizontal cooker after all.
There’s another description of using the Minion method in a horizontal cooker in this blog.
Again, since I’m frugal and use briquettes instead of lump coal, there is a lot of ash to contend with. So I’ve place the coal basket on the grilling grate high in the firebox.
Supporting grate
With the coal basket up high, there’s a lot of room for ash to accumulate and little chance of smothering the fire. Just be sure to shake the basket every once in a while. The ash is easily remove by pulling out the bottom drawer. There’s also a lot of air circulation around the basket to feed the fire
Firebox setup
Here I’ve put wood chunks in a smoker box.
When I load the basket I use around twenty hot briquettes. I place the hot coals on one end of the basket and cold coals on the other end. So I think of it as a modified Minion. The basket is placed in the firebox so the hot coals are nearest the cook chamber and the cold coals are nearest the vent. As air is pulled into the firebox it blows past the cold coals and feeds the hot coals. The fire is kind of pulled towards the cold coals rather pushed. With this setup a basket of coals will burn for 1 1/2 hours.
When the basket needs reloading, Close the exhaust vent then remove the basket to a separate grill. Shake out any ash and small chunks of coal. Then push the hot coals to one side and fill the basket with new coals.
Reloading
Here’s an eleven pound brisket ready to go.
Cooker primed and ready
I live in the suburbs and I’ve always been concerned about the smoke that drifts into our neighbors homes. Granted I love the aroma, the neighbors maybe not so much. Goodwill and smoked meats may reduce some of the possible aggravation. But it won’t get the smell out of their curtains and rugs.
So using some ducting, some tape, rope and hooks, this is what I put together.
Temporary chimney
Redirected smoke
The setup is put up for each use. Once the pieces are assembled, it takes just a few minutes to put in place. With the smoke released at roof height, most of it will dissipate by the time its gets to the fence. Now, I don’t worry so much about smoking out the neighbors and can focus on bringing fire, smoke and meat together.
Smoking
Char-Griller
