Help! Trying to assemble Char-Griller!

Discussion in 'Charcoal Smokers' started by gaga, May 10, 2009.

  1. gaga

    gaga Fire Starter

    Its 90+ degrees in New Orleans, and I'm sweating my ass off, and I don't know how to put together my Char-griller with the side-fire box. The instructions are confusing.

    Do I only knock out the firebox football and install a damper on the griller? Or do I knock out both footballs? How do these guys dance?

    Also, I bought the smallest dryer vent and clamp at Lowes and its not small enough. Has anyone experienced this? I'm crap at this.
  2. meowey

    meowey Master of the Pit OTBS Member SMF Premier Member

    I believe they both need to be knocked out so the heat and smoke can travel from the firebox into the larger grill area.

    Hope this helps!

    Take care, have fun, and do good!


  3. bassman

    bassman Master of the Pit OTBS Member SMF Premier Member

    You picked a poor day to get advice (Mother's Day). I know nothing about that type of smoker but I will bump this back toward the top and see if we can get you some help.
  4. Should be open football shaped hole between sfb & smoke chamber. Dryer hose should be 3".
  5. pigcicles

    pigcicles Master of the Pit OTBS Member SMF Premier Member

    Knock out both football cut outs and line up the bolt holes and assemble.

    As for the vent - let it go for another day if you're stressed and find one that is the size you want. Otherwise you will need to hose clamp it down until it's tight.

    Good luck.
  6. gaga

    gaga Fire Starter

    Thanks, y'all.

    However, I can't bash out the other football-sized cut out. I bashed it over and over again with a hammer. It won't pop out and I'm worried that I'm bending the side of the smoker!

    I guess I'll need to buy a hacksaw that can cut steel. I'm almost there!
  7. coyote-1

    coyote-1 Smoking Fanatic

    Yeah it's not the easiest pnch-out to remove. Just be careful and persistent and it'll work eventually.
  8. Put a phillips screwdriver where each screw hole will be & give it a good whack.
  9. mossymo

    mossymo Master of the Pit OTBS Member SMF Premier Member

    I recall mine being stubborn to knock out also (spot welder got carried away...), if you have a grinder or dremel that should get it started for you. Otherwise be patient and carefully whack away.
  10. mavrick813

    mavrick813 Smoke Blower

    I took a 2x4 cut to the length of the chamber and slid it inside to support the side of the grill. Then used a Mason chissel right at the weld with a good wack from a Mini Sledge.

  11. caljr

    caljr Fire Starter

    Knocking out the footballs are a big pain in the butt. I am sure you got it done by now but if not take the one that is giving you trouble back to Lowes and take back the dryer vent too. They will give you a new one. Ask them to knock it out for you or you will bring the whole thing back. They will oblidge. I had to take a saws-all to mine to get the one connected to the smoking chamber out. As for the dryer vent..Lowes does not sell a 3" dryer vent and that is what you need. Home Depot does sell 2 different kinds. A real cheap aluminum film dryer vent and a nice heavy duty flexible tube. You will find the clamp there also. I have attached a link to a thread that I posted which shows the mods that I made. Maybe you can find some ideas there. After you make the mods it is a great unit and I highly recommend it. It is well worth sweatin' in the Big Easy! If you have more questions I would be more than happy to help if I can.
    Happy Smoking..
  12. gaga

    gaga Fire Starter

    1. Carl, I am well aware of your smoker. I decided to model mine after yours when I first looked around this forum. Seriously.

    2. The football is still in there good. I've drilled startegic holes, thinking it would losen up, but I've whacked the crap outta that damn thing, and its still in there.

    3. I'm just gonna take a hacksaw or something to it. I don't have a grinder or dremel. No mason chisel. No mini sledge. I drilled out the holes with my drill, though.

    4. I wanted to get it ready for smoking this Saturday or Sunday. Now I got something extra to look forward to when I get off work this week.

    5. That football is gonna be history!
  13. caljr

    caljr Fire Starter

    I am glad that you liked my mods! This forum gave me plenty of ideas but I can take credit for the baffle design.

    I drilled holes too and it didnt help at all. After I got a corner removed, I used a pair of vice grips and spun them until it started to pop off. The problem with the holes that you drilled out is that once you get it started, it will stop at the drilled holes and rip into a different direction.
    I hope everything works out well for you. Good Luck!
  14. gaga

    gaga Fire Starter


    My tool collection is seriously lacking. Yesterday, while I was sweating, and cursing the football cutout, I kept on thinking about borrowing James Bond's watch from Octo*****, where it has a laser that can burn through steel. I only needed it for 2 minutes. Sigh...
  15. howufiga

    howufiga Meat Mopper

    Someone on here told me to do the same thing. I used 2 x 4 the length of the inside to support it, layed it down with the football knock out facing up and pounded it right out with a regular hammer. Came out real easy.
  16. gaga

    gaga Fire Starter

    You mean put the 2x4 next to the football cut out? Good idea.

    I'm gonna be smoking this weekend if it kills me, dammit!

    ps- Its too bad that so many people have had to deal with this "football" issue. Maybe someone oughtta put the 2x4 trick on a sticky or something. Just a thought.

    PPS- To all the Char-Griller owners, two questions: 1. Did you plug up the holes on the bottom of the main chamber? 2. Is the thermometer leaky? I bought some thermometers that I'll install, but I'm worried that the factory thermometer is gonna leak. The seal is very loose.
  17. howufiga

    howufiga Meat Mopper

    Yes, check out my primitive drawing! lol You want the 2x4 cut the length of the inside of your chargriller and move it around while you knock out football withe hammer. Take pics and post if you can!

    The factory thermometers stink. I've installed 2 aftermarket thermometers at grate level. The chargriller leaks all over the place. There is a sticky dedicated to Chargriller mods. Check it out
  18. bigsteve

    bigsteve Master of the Pit

  19. caljr

    caljr Fire Starter

    I personally did not plug the holes on the bottom. I dont think there will be too much heat loss. After I completed my mods I was seasoning the smoker (see below) and I had a ton of smoke going to see if I still had leaks and nothing was coming from the holes on the bottom. I am sure it wont hurt if you want to do it, just get nuts and bolts that are not galvinized.

    The thermometer leaks but it is going to be the smallest leak you have. Ace hardware stores sell a high heat silicone which you can seal it with if you want. You can also use the gasket adheasive that I used for attaching the gasket but it will be pretty permenant at that point.

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