How to use a Smoker Box on a Gas Grill

Think you can’t get great barbecue flavor on a gas grill? Think again. Here is the ultimate guide grill reviews on how to use a smoker box on a gas grill, with tips from how to choose a box, how to fill it and get smoke, debunking the myth of wet or dry tips, and more!

When I first started using a smoker box I had a lot of questions! How many wood chips should I use? Wet or dry wood chips? What size of a smoker box and where the heck does it go on a grill?

Through research and lots of smoky experiences, I have almost reached the finish line of mastery. But Wait! Do we ever stop learning from our grills and smokers? No, because fire, smoke and smoker boxes can have a mind of their own. However, there are tips that can help us not to make the mistakes that those who have gone before us have.

Let’s jump into a quick course on Smoker Boxes before we “smoke-up” some delicious Smoked Chicken Thighs with Salsa Verde Charred Corn!

What is a Smoker Box
Smoker boxes come in many shapes and forms. Some smoker boxes are dotted with holes all over while others have air holes just at the top. You will find cylinder shaped and rectangular boxes. There is even a V-shape box to fit between flame deflector bars on gas grills for an intense smoke flavor!

No matter how many holes or the shape, a smoker box is a heat-resistant metal box that is used to hold the wood chips or what Western BBQ calls smoking chips.

What Smoker Box is Best
Poll the pit masters to what smoker box is best, and you will find a wide array of answers.

Stainless Steel is the most common material used in making a smoker box because it retains heat well, resists rust, corrosion, and staining. Look for the thickest steel box on the market to avoid warping. A quality smoker box provides consistent smoke, and can be used for many years.

Aluminum is extremely lightweight and can be used one or two times. If you do use a disposable aluminum smoker box DO NOT put it directly on the coals or heat source. Aluminum melts under high heat, YES, I did make that mistake as a rookie.

Cast iron is less common and more expensive than stainless steel but it is the most durable. A cast iron smoker box can last a lifetime when properly cared for. The con of cast iron is that it does heat slowly therefore the smoking chips take longer to do their job. The pro of cast iron is that due to the box heating up slowly and retaining heat more efficiently than steel the stream of smoke will last longer.

Wet or Dry Smoking Chips
Sure there is a debate on wet versus dry wood chips! But through observing expert pitmasters, smoky experiences, and trial and error, dry smoking chips wins! Fill up a smoker box with wet wood chips and you create steam, and steam does not produce that signature barbecue flavor.

Start with dry chips to really infuse your food with the best flavor.

A homemade aluminum smoker box that has lots of holes for the smoke to release.
Poke holes in the top of a homemade aluminum smoker box.
How to Use a Smoker Box
Filling a smoker box with wood chips is pretty simple, right? Yes, but there are a few mistakes that will hinder the development of smoke.

Don’t Over Stuff the Smoker Box
Smoke needs air! An overstuffed smoker box, with the lid closed, does not allow for air circulation.

Go Low and Slow
To produce an alluring smoke that lasts for 30-35 minutes your goal is to swelter the smoking chips not to set them on fire. If a smoker box is set directly on the heat source, gas burner or embers the wood chips will catch on fire in the smoker box.

Smoke development takes time; place a smoker box above the heat source not on the heat source! On my gas grill, a smoker box filled with 1 1/2 cups smoking chips, placed above the hottest burner, will take 15-20 minutes to produce smoke.