Smoker From Old Weber Kettle Grill

In 2015 I had an old weber kettle grill that I wasn't using anymore since I had a nice new gas grill so I decided to use it as a smoker.

First started with using a 'Smokenater' insert but switched to a 'Slow-n-Sear' insert in 2018.

Have made pork ribs, beef ribs, brisket, chicken, turkey legs and ribeye over the years.

For this instructable, we are going to make St. Louis style pork ribs.

1. Old weber kettle grill
2. BBQ Guru DynaQ Temperature controller
3. Heat Proof gloves
4. Scissor Tongs
5. Slow-n-Sear insert
6. Chimney Charcoal Starter
7. Charcoal briquets like Kingsford

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I am planning for the ribs to take about 7 hours at 230℉.

So I want to get them in the smoker around 11:00 am for a 6:00 pm dinner.

I used Smithfield St Louis Style ribs from Wal-Mart for this smoke and prepped them 2 hours before I wanted to start them on the smoker. (i.e., 9:00 am)

2 full racks 7.22 lbs in total weight.

So the smoke can penetrate the meat sufficiently, it is important to remove the membrane on the 'non meaty' side of the ribs if it is present. Insert a butter knife near an edge to get it started and then peel the inner membrane off - using a paper towel to grab onto the membrane makes this an easier task (see picture). Also, remove any loose bits of fat and bone.

I cut a full rack into half racks so they will fit into the smoker. Usually there are 14 ribs to a full rack so I just count to the seventh rib and cut it there.

Rinse off the rib rack with cold water but do not dry off - the wetness will help the seasoning adhere. I generally want to use 1/2 tsp of salt per lb of meat but since ribs are about 50% bone, I use 1/4 tsp of salt, or salt equivalent.

Season with your favorite rib rub. I used BBQ 3000 from Penzy's spice company. Since this spice has salt in it already, I used 3/4 tsp. per side for each of the four pieces.

Cover with plastic wrap and set aside at room temperature.

I use a small table near where I am going to smoke to hold the supplies I am going to use.

On the table are the heat proof gloves, tongs, bbq guru temperature controller and the chimney charcoal starter. There are links to these supplies in the supplies listing above. (Note: I am using the 'PartyQ' from BBQ Guru I purchased in 2015 - it is not manufactured anymore and has been replaced by the 'DynaQ' model.)

Put the Slow-n-sear insert into the weber kettle as shown in the photo. I put mine on the side of the grill with the '1 leg' opposite the side with the wheels. This is the side I will point into the prevailing wind while using the smoker.

Fill the insert with as much charcoal as it will fit - usually this is enough for 8 hours of smoking.

Take 15 pieces out and put them in the chimney starter with newspaper crumbled into the bottom of the chimney and light the paper.

Check after 15 minutes and all the charcoal should be lit.

After the coals have caught fire in the chimney, dump them on top of the charcoal in the insert.

Add 2 cups of water to the insert in the 'well' - this will provide steam during the first part of the smoke to help develop the smoke flavor.

I also use a catch pan I place on the lower grate to catch the juices so they don't get all over the place I'm smoking at. (See first photo)

Insert the BBQ Guru (see the instructions that come with the BBQ Guru on how to get it installed). I drilled a small hole in the side of the Weber to put the temperature sensor wire through so it doesn't get kinked in between the lid and body of the grill. (See second photo)

Set the BBQ Guru to 230℉ and put the top on the grill. I put it so the vent circle is over the side with the wheels and farthest away from the '1 leg' side.

Since my weber is very old, it doesn't seal that well. I use 3 large size binder clips, space evenly apart, to help keep the lid sealed to the body. (See third photo)

Once the temperature is stable at 230℉, place the ribs on the grill rack. It can be difficult to load them all on but do the best you can - they will shrink a bit during the smoke. (See cover photo)

Add the wood you are planning to use - should be a hardwood like hickory or oak. Place the wood directly on top of the coals - I use my heat proof glove to pick up the grill so I can then put the chips on top of the coals.

Do not soak your wood in water - it doesn't do anything...dry wood is fine...

I am using hickory for this smoke.

I will put in 4 ounces now and another 4 ounces in 30 minutes - that's all you need!

Adjust vents to keep temperature as close to 230℉ as possible. After 3 1/2 hours, turn the ribs 180° so the other end is near the 'hot side'.

After seven hours this is what they look like - see image 1.

Grab one end of a slab and move it up and down to see if the surface forms a 'crack' - if it does they are done - see image 2.

In image 3, you can see the slight pink 'smoke ring' near the surface of the rib.

These came out great - cut easily and came away from the bone cleanly!

Ate them with some bbq sauce on the side, homemade coleslaw and a piece of cornbread.

Enjoy!