Love the convenience of your gas grill but crave that authentic smoky flavor? You don’t need to invest in a dedicated smoker—with some simple DIY smoker box modifications, your gas grill can produce impressive smoked results. This guide will walk you through creating, optimizing, and using smoker box setups that transform your gas grill’s capabilities.
Why Modify Your Gas Grill for Smoking?
Standard gas grills have limitations for smoking:
- Inadequate smoke retention due to design
- Poor temperature control at lower smoking ranges
- Limited wood chip capacity in store-bought smoker boxes
- Inefficient heat distribution for indirect cooking
With thoughtful modifications, these issues can be overcome.
Basic Smoker Box Options
Start with these foundational approaches:
1. Commercial Smoker Box Upgrades
Improve store-bought options:
- Drill additional ventilation holes for better airflow
- Create a raised platform for optimal placement
- Add a divider for multiple wood types
- Install a hinged lid for easier refilling
2. Repurposed Container Conversions
Transform household items into effective smoker boxes:
- Heavy-duty aluminum foil pouches
- Puncture 8-10 small holes on top
- Fold edges securely to contain chips
- Place directly over burners
- Tin can smokers
- Remove top completely
- Punch holes in bottom and sides
- Create a loose-fitting foil lid
- Cast iron containers
- Old camping cookware
- Small Dutch ovens
- Cast iron ash containers
Placement Optimization
Strategic positioning makes a huge difference:
Direct Heat Placement
For maximum smoke production:
- Position directly above an active burner
- Place box as close to flame as possible
- Use heat shields to prevent excessive chip burning
- Consider partial burner coverage for temperature control
Indirect Configurations
For longer smoking sessions:
- Between active and inactive burner zones
- Elevated on a small platform for airflow
- Under a corner of cooking grates for space efficiency
- Multiple boxes positioned strategically for even smoke
Advanced DIY Smoker Box Projects
The Multi-Chamber System
Create a versatile smoking solution:
- Main chamber for primary wood chips
- Secondary chamber for supplementary flavors
- Water reservoir for humidity control
- Connecting tubes for smoke distribution
Materials needed:
- 2 small stainless steel containers
- High-heat silicone tubing
- Stainless steel mesh
- High-temperature fasteners
The Integrated Drawer System
For convenient refilling without opening the grill:
- Create a sliding drawer mechanism below grates
- Install heat-resistant handles for safe access
- Build adjustable vents for smoke control
- Add removable dividers for different wood types
Materials needed:
- Stainless sheet metal
- Drawer slides rated for high heat
- Heat-resistant handle material
- Metal cutting and bending tools
The Full-Width Smoker Tray
Maximize smoke production and distribution:
- Custom-fit to your specific grill model
- Multiple compartments for different wood types
- Integrated water channels for moisture
- Adjustable vents for precise smoke control
Materials needed:
- Sheet metal (16-gauge stainless preferred)
- Metal bending equipment
- High-temperature rivets or bolts
- Expanded metal mesh for internal supports
Grill Modifications to Enhance Smoking
Beyond the smoker box itself, consider these grill modifications:
Sealing for Smoke Retention
Prevent smoke from escaping too quickly:
- High-temperature gasket material around lid
- Silicone seals for any visible gaps
- Magnetic door latches for tighter closure
- Vent dampers for airflow control
Temperature Management Additions
For better low-and-slow control:
- Secondary thermometer installation at grate level
- Heat deflector plates for even temperatures
- Brick or stone inserts for thermal mass
- Wind barriers for consistent temperatures
Airflow Enhancements
Improve crucial air circulation:
- Adjustable intake vents near burners
- Chimney extensions or added vents at top
- Baffle plates to direct smoke path
- Convection fans for more even smoke (battery-powered options available)
Wood Selection and Preparation
Optimize your smoking medium:
- Size matters:
- Chips: 30-45 minutes of smoke
- Chunks: 1-2 hours of smoke
- Pellets: Consistent, controllable smoke
- Preparation techniques:
- Soaking: Controversial but extends smoke time
- Pre-charring: Creates cleaner smoke faster
- Mixing varieties: Creates complex flavor profiles
- Wood positioning strategies:
- Layering different woods for progressive flavor
- Creating “smoke packets” with varying densities
- Strategic placement for consistent smoke release
Troubleshooting Common DIY Smoker Box Problems
Excessive Wood Consumption
If you’re burning through wood too quickly:
- Reduce direct heat under the box
- Create a dual-chamber system with indirect heating
- Use larger wood chunks instead of chips
- Add a small amount of damp chips to dry ones
Poor Smoke Production
For inadequate smoke:
- Increase ventilation holes in your DIY box
- Position closer to heat source
- Use drier wood for better combustion
- Try different wood varieties with varying oil content
Heat Management Issues
If temperature control is challenging:
- Create a water pan barrier between flames and smoker box
- Use fewer active burners at higher settings
- Add thermal mass to your grill
- Implement a two-zone heating system
Innovative Combinations
Take your smoking to the next level:
- Pellet tube integration with chip boxes for dual-smoke sources
- Cold smoke generator attachments for true cold smoking
- Automated temperature controllers adapted for gas grills
- Smoke circulation fans for even distribution
Final Thoughts
DIY smoker box modifications allow you to transform your gas grill into a surprisingly capable smoking machine. Whether you opt for simple aluminum foil packets or elaborate multi-chamber systems, these modifications open up a world of flavor possibilities without investing in a dedicated smoker.
What creative smoker box modifications have you tried with your gas grill? Share your innovations in the comments below!