Chargriller Offset Smoker Mods

I bought a Chargriller Deluxe Grill, which becomes a Smoking Pro when the firebox (sold separately as a Portable Grill) is added to the side. I noticed lots of smoke leakage, and decided to "tighten up" the cook chamber, and generally improve the build quality. Small little things, but here's how I did it.
Original Music By:
"Fork and Spoon" Kevin MacLeod (incompetech.com)
Licensed under Creative Commons: By Attribution 3.0
creativecommons...

[@hillbillydan4721]

I got one from our church about 12 years ago we had a storm blow down a couple of tree limbs and one of them landed right on top of the smoker, just folded up the legs but both boxes are fine ! The church bought a new flat top and they gave the old one to me ! Anyways, all I've done to it is JB weld the seam between the 2 boxes as I was losing a great deal of heat/smoke in the seam, put a metal plate in the bottom to cover where the heat/smoke has to stay on the bottom, extended the smoke stack down to the grill surface like you did, made a new frame to hold the boxes,and I repaint it with high heat grill paint every fall, and I also added a couple thermometers in the door at grate level !! Its still rockin, use it several times a year !

[@timothybueschel7114]

IVE GOT THE SAME SET UP AT HOME AND NEVER HAD A HARD TIME REGULATING ANYTHING. THE HEAT STAYS BETWEEN 225/250 NO PROBLEMS AND I HAVE THE SAME LEAKAGE ISSUES YOU GUYS DO. IVE HAD IT 1 YEAR TODAY AND LOVING IT.

[@juliankirby9880]

Timothy Bueschel quick fix is fold some tinfoil over the bottom lip. Also works on the Weber kettle really well. I just got an offset, and it’s super easy to control, but I’ve only used it 3 times so far

[@cmanofthewoodscentralus3217]

You talk about buying a dryer vent to extend your chimney pipe. What I have done is purchased a roll of aluminum flashing six inch for what I was needing, and wrapped around the pipe the pipe marking it about an inch longer so it will overlap and use a hose clamp to hold it to the position I want from the meat on the grate. This gives you the adjustment that you may like. Good video.

[@jefflundquist5771]

Hi Tony. Thanks for the video and mod suggestions. I have the very same Char-Grille unit, just picked it up last night as it was on sale. I'm going to do the mods right away, and then the initial burn in. I have hot-rodded a few other smokers in the past with good success. Cheers!

[@CHIEFmschf]

Yea I tried doing the glass around the firebox lid and with the 3/8's inch rope it was a little to much. Even tried the flat version of it and it was still to thick. It pulled it up just enough to cancel out the 3/8's I put along the side and lower section of the lid. Ended up making a gasket with RTV for the top lip and it has just enough cushion to compress and seal it off nicely. Even using the 3/8's glass on the side lips I was only able to go 3/4 of the way up before it started lifting the lid out of place. So I just cut it there and made that the starting point of my RTV gasket. Not as cosmetically pleasing, but hey it works. Great video though! Inspired me to get mine into shape.

[@EKINGKONG387]

Thanks....a lot of cool ideas! Keep up the great work!

[@FloydeXXNatural]

Dude.. Idk what the rest of your videos are on or anything. But just from the quality of this video and the quality of you and your work. I am subscribing right now. I'm impressed and it is inspiring and motivating to see somebody with the attention to detail you have. And the pride you have and instill in your possessions. Cheaper things can work more than well enough and can last as long as you, when taken care of. More people need these lessons and values. I just bought a used one of these and wanted to take it upon myself to rescue the poor thing. Plus, a good cleaning or not, 25 bucks was a good deal. But now I find myself needing to mod it just as well lol. Thanks mate!

[@eaglescout9901]

Very thorough explanation for your first or 100th video, keep them coming. . I have one of these and will be purchasing the side box. I like the idea of lava rocks to help hold the heat as they do on my Charmglow 2000 Propane grill. Also I will use the red silicone hi temp caulk and dryer vent. Thanks for sharing your ideas, it does help see what others are coming up with then we could replicate or tweak.

[@RobsBackyardBBQ]

I wouldn't worry so much about all of the leaks - as long as it's mostly tight, you should be fine. Great video though - subbed! I just put one up as well with mods on the char-giller.

[@ih8texas247]

What's the link to your video

[@vegasrenie]

You're way overdue in letting us know how everything worked out!

[@bonespec]

Loved your video, can't wait to mod mine! I have used two bath towels on the top to hold heat in as well.

[@guillermoparedes6450]

Let's see the gaskets in action. I like how you put angles on the side.

[@thebeerdedone7568]

Thanks for this. I love modifying things. I have this model and just attached the fire box

[@johnoborn8746]

My wife just bought me this, great vid. Thankyou Cheers John

[@MrSoup6029]

I just replaced the firebox on mine after 8 years, it was rusting out. The spacers should have come with it.

[@christopherjohnson7767]

Thanks for the Vid! I am going to have to do lot of the same mods you did. My smoker box lid is the main source of smoke losss at the moment..and the back of my cooking area.

[@chriskibler7998]

Adding the L channel is about the only way to get the smoke to stop leakig. Mine is not as good of fit.one side hangsoff about a half inch.Good to know about the glass rope. Happy smokin!!!

[@TrotterVideography]

Nice video Thomas. I have the same smoker and have made some great smoked turkey for thankgsgiving on mine. I loved the modifications you made. I am also going to extend the smokestack chamber near grate level on mine too. I see some guys actually making a smoke stack for their side fireboxes as well.

[@MrSoup6029]

Nice video. I have been meaning to do something about the main lid seal, and I will be doing what you did. Thanks

[@themackguyverchannel7713]

When you buy one new the firebox comes with the supports which bolt to the frame. You can use carbon felt for a gasket too which works really well.

[@autonymous]

I'll try that carbon felt. My side box didn't come with spacers or I'd have used them.

[@iamthedonjuan]

I have that same BBQ, bought the offset later to attach. the hardware to attach the offset does come with the bolts and spacers that attaches to the predrilled holes of the cross bar frame. with the spacers in place there is no wobble or shaking. double check the hardware that came with the offset unit for the spacers.

[@autonymous]

Then I got a bum unit, none of that hardware was listed in my parts sheet. So I did it myself. Things might have changed in the 4 years since I bought the thing.

[@JasonLMair]

Great ideas that will help me mod the exact same grill! Thanks.

[@autonymous]

*Here's How I Modded My Smoker* Last summer, I got a Chargriller Deluxe grill. But I always had a sneaky suspicion that despite the large cook area, I still wouldn't be able to do the type of indirect cooking I wanted/needed. Turns out I was right. So, I ended up adding the firebox to it. Well, the first couple times I used it with the firebox, it leaked heat/smoke from everywhere, and I ended up having to "fix" it. This video shows me getting started on fixing it. Too bad the couple little things I did could have been done at the factory for just about nothing during the manufacturing process. But, at least I learned a little more about my rig in the process! #bbq #hacks EDIT: I did these mods back in May, just never got around to editing the video and posting it...

[@dhoppsbbq]

Sweet smoker mods Sir!!!!

[@autonymous]

Yours is next. You fix that hole?

[@dhoppsbbq]

Not yet

[@henrylee4346]

Tony Thomas

[@trippingonfaith7094]

I’m considering the same setup only because these grills are very deep can run ribs vertically but they are a bit cheap!

[@garrettlynch1041]

Did you take the dampener plate off the grill to attach the offset smoker?? My char broil dampener doesn’t not have nuts or bolts attached to remove it. There’s only 2 holes up top and 2 holes on the bottom just outside the dampener plate. Can i get by without taking that whole plate off and can the dampener holes work well enough to push heat and smoke through??

[@brandar75]

I have a Chargriller...GREAT grill..not so great smoker (for the reasons you mentioned -too leaky). Check out the PBC....best smoker I've ever used, and easiest, as well. Was recommended to me by a friend who does comps... I couldn't be happier.

[@autonymous]

brandar75 Yeah, I'm SERIOUSLY considering a PBC. Too much to do this summer, may not be cooking much.

[@kennethgensler5855]

Funny thing is, I can smoke with just the barrel just off setting from the heat. Gotta learn how to control the grill!

[@denisefoerter3256]

That shaking smoker box is caused because you forgot to put spacers and long bolts and nuts that attached thru box to the grill's frame. they come in the pack od nuts and bolts. Those two spacers cones around 3 inches long with provide enough support to stop the instability of shaking weight of box.

[@autonymous]

Thus is an old post, but if you didn't hear me: I didn't get the spacers because the fire box didn't come with the grill originally. I added it about a year later. The firebox didn't come with the spacers either

[@earlhudson7759]

Nice video, have the same smoker, not the best I've used, but it's ok. I put the rope on the bottom instead of on the top and added 1/2"x1/8" gasket on the back of the bottom half of smoker. I believe I like your way better, in regards to putting the rope on the top portion of smoker.

[@hillbillybbq]

Man thanks I got the pro and I can not regulate the temps on it! And just wondering.. on long cooks how do you empty the ashes so it will breathe? I wonder how it would work to build the fire on top of the grates so you can pull out the ash drawer?? I'm gonna try it. Let me know your opinion. Thanks so much for your video buddy!

[@jlp7184]

Maybe i missed something. Did he say he only cooked on this grill twice and it's in this bad condition?

[@SnowHunter44]

you could get flat tape for the firebox lid!

[@Polamish]

well done sir. thank you

[@bacardi2001]

what size was the angle? and it was aluminum right? how high up off the lip did you mount it? thanks and good job

[@at5488]

The smoke box should have came with spacers. Mine did.

[@autonymous]

AT5488 cool. Mine didn't.

[@djsal617]

Good video...did u mod the inside of the offset box and the grill or did u leave the offset the same way...cause I have the same grill and just picked up the offset from my neighbor..but not sure if I have to cut the smoke exit more from how it is..

[@redz3]

best explanation yet!!! what size angle bracket did you use around the top lid? just bought the same one and have the same exact probem

[@rtbubba]

Great video!

[@elektrovert]

This is great! Exactly what I was looking for. I was thinking I might have to get someone to weld plates onto the lid, but your L shaped aluminum pieces screwed into the lid is a much simpler, more elegant solution! Thanks, I'll be implementing all of your fixes. Did you use the gasket rope on the back of the lid in the end?

[@autonymous]

elektrovert I never did. It's working pretty well for what I managed to fix so far, but if you're going to do it, go right in for the back while you're doing the sides. It's on my list for this summer, right behind the vintage boat I'm restoring.

[@jackiehughes2261]

elektrovert Alaska an saw mill

[@afarley17]

hello, where did you get the brackets to stable the fire box and what size are they?

[@chartle1]

I'm assuming its just a few bent pieces of metal. You are just going to have to look around a hardware store and see what works.

[@addisonwilliams2221]

I’ve never understood these people mod pit leaking sides and back. The smoke rises to top want exit fast is pushed down past meat exits sides and back....

[@jibba0202]

To make fire you need oxygen. A few gaps in the door is not doing any bad for you

[@josephscroggins1071]

Bro, did the smoker still leak? How did things work out?

[@r3deag1e]

nice mods.. can you tell me where you got the brackets for the smoker box?

[@autonymous]

I made 'em. Cut a couple of 5-6" pieces of 1" flat aluminum bars, bent them into U shapes, and drilled a couple holes through them.The fire box and the main grill leg bracket have holes that lined up, so I put the brackets in between, used machine screws/nuts/washers to hold in place.

[@jamesk1619]

Tony Thomas thanks!

[@RandyH400]

Smoke box wouldn't flex if the spacers & nuts & bolts were installed when assembled

[@deloresevans187]

I have a question. How does the grease can holder go on.

[@tommywoo1888]

Thank you and great job...…. I am going get Yoder Cheyenne by 3-2020 (Yoder.com).

[@RandyH400]

I didn't use dryer vent I used flex exhaust pipe. (Automotive)

[@MrRustyBob]

Actually ?

[@williamjones6053]

You get what you pay for ..metal is to thin to hold heat ..go buy a Oklahoma Joe reverse flow ..they are cheap and work way better than that one ..Yoder's are good and fairly cheap as well

[@eflowers765]

Like your video but it made me dizzy