Char Griller Pro (COS) Mods The BEST Modifications You Need! 

I have a similar setup from the same manufacturer, this man knows what he’s doing. Fantastic video.

Thank you for taking the time to make this!!!!!!! I just bought my grill last night and as I put it together Ill add these kids.

Thanks for the share I've had mine since about 2002 and was looking to figure out a way to modify it went through several grates. Hard to admit but I don't think I've ever used the smoker the way you've used it but that was genius

Great video. I've had a Chargriller Pro COS since 2003 and I keep saying I'm going to get me a fancy pit once I kill this thing, but it keeps on chugging. I like your mods, especially the drier hose and the baffles. I may postpone that stainless steel beauty I have my eye on and put a few hours of work into refurbishing mine into something like what you have. Again, great video. You know your stuff.

Thanks Scott, I've just bought a side smoker box for mine. I'll be modifying it as you suggest. Beers & Brisket this 'arvo. Cheers mate.

Thank you, I was looking to replace my char griller with an upgrade, but now I'm just going to take your advice

I now have a plan for my cooker i just picked up. Thanks Scott. It will be smoking good this year.

Thanks for the tips, I just picked one up at Aldi for $75 on clearance. Smoked my first rack of ribs and some wings, they came out amazing just using firewood.

thanks for the guidelines, great ideas and solid performance now. i used that rope seal on front lid and back edge and it's night and day without losing that heat from those long sides. i also put rope on the firebox door, but have to use extra weights to keep it closed. it does help though. i had a helluva time finding 3" exhaust pipe and the 4 was just too tough to work with. i ended up using plain old foil, wrapped around a baseball bat, and taped in with foil tape for a good seal. budget friendly version too :) found an old cookie sheet that acts as my baffle from the firebox. i like your version, but am not that handy with heavy metal. :) thanks for the great tips, helping to bring back my old beast from near retirement to going to a competition in April.

I was almost of the mind to scrap my CharGriller COS and buy a pellet smoker. However, after watching your video and a few more about the mods, I changed my mind. My COS is about to get modded this weekend to smoke a brisket. 👍

Great inspiration on some mods for my COS. I dig the heat baffles coming up from the wood box, your temps look pretty dang even. I just moved up to a COS from 'smoking' on a propane grill the past few years with chip boxes and wet chips...wow what a difference. First cook was a complete success. Practicing on propane only did me one favor, my spice rubs lol. Totally different heat management system involved. I'm gonna work out some of those baffles too, too much of the heat jumps right to the lid, so that should really help out. Thanks for the vid, was good to learn from your experience.

Man, great work. I just picked up a new braunfels smoker (used, $5). These mods are just what I was looking for. NC born and raised so I can't just fire up any old thing and expect good results. Up to this point I've pre-cooked in the oven for one hour at 350 and then back it down to 225 for three hours then finished the job on a gas grill, offset with a cast iron smoker box. Always got kudos but ready to take it to the next level. Thank you.

Thanks for the video. I've owned a chargriller for years. Just got one with a smoker on it, so I've never smoked anything before, have done alot of research. I plan on keeping both grills. One to grill with....it needs a new ash tray, and imagine that I got one now! lol I don't have the luxury of knowing anyone or finding scrap so probably will have to buy everything....and I dont have any metal cutting tools...oh boy.

Thanks for sharing Scott. I was thinking about adding baffles to even out the temperature but would have never thought to add the duct down to grill height. I'll be working on my mods this week and smoking on the weekend!!! Thanks for the link to the thermometers too.

I had a piece of exhaust pipe that fit perfectly to bring it down near grate level. Helped even out the temp on that end.

Nice video. I have been meaning to add two wheels to mine. It can be horsed around but damn, it's heavy! I also also added upgraded thermometers at grill level 2" from each end, like yours. The mod I did different in the smoke chamber is I made it reverse flow rather than just baffled. Initially I cut two pieces of angle iron off an old bed frame. Then I drilled two holes in each, lining them up with the bolts at the front and back that hold the body to the frame. So they bolt right on where there are already bolts. Then I just turned the charcoal chamber over, laid it on the angle iron and butted it against the fire box end. Smoke now had to go to the other end before going up. This brought part two of this mod; removing the smoke stack and putting it on the other side. I mirrored the hole over and bolted it in and then bolted a piece of sheet in the old hole. It worked pretty good with the temps within 1-2 degrees at each end. I found the angle iron was at the edge of being to short so the inverted pan could slip off if I moved the smoker. Plus I wanted to put a couple of big cookie pans under the grates so I revised the mod. For $20 I got a nice stainless steel reverse-flow bent edges plate. It fits a lot better and the top being flat makes it easy to put the drip pans underneath. I like the expanded metal grate in the fire box. I copied what many others have done there and made a basket for mine. I have gasketting material but have not done that mod yet. What I do instead is just roll up some long pieces of foils and press them on the lower barrel. The work pretty well for a smoke or two then i toss them and do it again. It helps a quite a bit.

Thanks for the vid. very basic and seems really easy. I have the exact same grill without the burner on the left side. Will try for sure..

Scott, just bought a used char griller for 20$ and glad i came across your video. i watched til the end and saw ur fishing rods and got me curious on what you fish for. Your channel looks awesome man. Alot of the same interests as me. Going to destin for my first deep sea fishing trip for the big un. Keep up the good work man.

Great video. I built a UDS smoker but I just bought the offset fire box for my Char- Broil and your video popped up with the mods. I learned a lot....thanks.

GOOD JOB!!!!! Iv'e had one of these for years.I'm going to make these Mods.I did add a couple of thermometers and a heavier grate in the fire box. Iv'e had mine for over 15 years,always stored inside when not being used.

I"m new to this. I just bought an off-set smoker. Thanks for your ideas. I'm so going to borrow them ;)

Cool Modification! I will do the modification on my Char-Griller.

Great video; I liked the modifications you applied to it! I just got one.

Thanks for the info! Going to do these tips asap!

I agree about that fiber tape stuff - it gets all over and smoke is gonna get out regardless. I just put up a short video of mods for my COS. Subbed!

Hey Scott, Nice modifications and one excellent video describing how everything works! Thanks for sharing the video, enjoyed it! I could smell those ribs all the way down here in Texas! Take Care!

Your modifications are genius. Great work bud !

Nice smoker. This is way cooler than a fancy pants expensive smoker

It's only purpose in life is to plug the hole 😂😂😂 I'm subscribing

cool ive just got one in newzealand cant wait to get it going !! cheers

Love all of the mods to your smoker. Gonna have to do the same

I need some of these mods for my offset smoker. Bookmarking this vid :)

It is super hard to find expanded metal mesh sheets where I live. So I used a cut down cast iron grill plate instead. works well.

thanks for the post, cool video.

Simple, Effective, and to the point 👍👍👍

You are not kidding about the paint. It actually says in the instructions not get the grill over 400°F. Mine peeled off right at the vents where it was near the coals.

Simple ideas but very very useful

wow, thanks so much!

Thanks for sharing this video, this weekend I just picked up the Char Griller Smoking Champ at a liquidation sale. I will probably put it together this weekend and have been looking at everyone's customizations. It seems that the bricks, baffles and dryer vents are definitely the way to go. I love your presentation with your upgrades and I would like to keep it that simple. I am planning on building a fire basket from expanded metal. I do have one question. I noticed you haven't talked about putting RTV all over this thing like I have seen in every other video. Do you see the need to do all that sealing of the firebox and cook chamber or putting those lavalock gaskets? Did you seal your smoke stack? I would love to be able to keep it simple like yours. Thanks!

Love the video, any chance you could let me know best brand grill thermometers to get? I’d hate to buy another one from char griller as mine took a shit tonight and now ill be modifying it anyways thanks to this.

I just got one Of these bad boys and I try to find excuses to use it everyday. I use mesquite wood and mannnnn! This think kicks ass.

Just have to say great mods !! I'm in the UK and have my char-griller turning up next week and looking forward to my 1st smoked brisket for my sons birthday... Will definately be doing ur mods, any advice would be greatly appreciated !!! All the best from the UK

Brilliant technique 😎

How did you attach the dry vent hose to the base of the smoke stack? My char-griller did not come with the forward facing wooden shelf. I'd like to add that to mine. The shelf on the side is not very useful.

Nice info. Just bought one myself

Hey great ideas man looks amazing...how to u get the thermometers on front of grill...did u screw drill holes in and the slide threw... please explain what u did to connect those.. thanks

Beautiful thanks

Thanks for sharing these mods. I'm surprised to see you can get an even temp with an "overbite" lid like that. I don't get why/how someone thought that design was a good idea. Is there anything close to a seal on the CC, or is there really an 1/8" gap when the door is closed?

Scott I just purchased this and I have gone through a whole bag of charcoal and 3 bags of hickory chunks on a 10lb pork shoulder and It has been 19 hours and It is only at 175 degrees.........It is leaking SO MUCH from the main grill where the top connects to the bottom, it leaks all the way around. I wedged some aluminum foil all around and it diddnt help at all. Any suggestions?

5:25 Where can I get a dog statue like that, it looks so real

This was a great video, and the mods were helpful. This is what saved you from getting a thumbs-down - which I wanted to do as soon as I saw those charcoal briquettes! You gotta use natural lump charcoal my man!!! hahaha Take care

That's a huge gap in the corner of the fire box, can see the grass behind it, 😳 tough to get a steady temp, with that extra air coming in

A rope gasket with adhesive should be included with these grills the gaps in the lid are huge

really help I going to smoke a turkey on my DUO, I will let you know how it goes

can i use this for regular grilling?

Good video, great ideas...thanks for sharing!

I heard the familiar sound of a longneck open at 48 seconds in

I wanted to ask you - I recently bought a COS and on the first cook; the fire box's paint began to flake off and fall to the ground. Would you recommend taking that grill back to the department store or just hit it with some grill paint after sanding? I feel that if I switched it out, it would just do it again. Cool vid - I am digg'in those modifications. Jeff

great video! cheers from St. Louis!

Thanks for the advice on the gasket, keep it simple . I have my very first butt on my brand new smoker right now. What you are doing make since to me , It is all about the draft. can you help me find the hose. I am not real sure what you used? Thanks Rhonda

Thanks for the post

My chargriller only has the pinwheel vent going from the firebox to the grill and I'm not sure if that's the reason, but I'm not getting enough heat. The smoker is only getting up to about 150 degrees. Thanks man!

Excellent video!!

Great video thanks for the tips

Great info! I just picked up the Duo grill, going to convert it into a smoker. Do you have any videos on fishing?

You didn't share how you were about to add the extra set of wheels. I just bought a 3 BURNER GAS GRILL 3001 and it could really use another set of wheels and a handle. How did you add the 2 extra wheels and have you ever added a handle?Thanks, Sam

Great Info - Thanks !!

really great mods

You run 250 with 2 tins of charcoal!? My char griller pro over Temps with a single tin of lump.

Nice video. Will be doing this mod this weekend. Where did you get the second set of wheels?

I like this video. Question, are you using a rigid or semi-rigid duct for the stack?

Great vid. Did you have smoke leaking out anywhere and did you do anything about that?

Nice vid bro !!!

Awesome! Very helpful, ready to get mine ready for baseball season BBQ'S!

Thanks for inspiring me to finally mod my Super Pro. What wheels did you pick up for your 4WD version? Having trouble finding anything at Lowes that looks like it will fit.

Common people. Ya'll know you checked your phones at 0:46 to see if you got a text message. 😂

great ,thank you

Snowbird: I'mm working on the gasket mod now but having trouble. The kit I got was too thick in the rear and won't allow the lid to shut. I'll have to remove that and start over. The other things bugging me is I can see the fiberglass coming off of the gasket material. That bothers the hell out of me and I might just rip the whole thing off and forget about it. It's not so bad that I want fiberglass in my food, you know? So far a giant P.I.T.A. if you know what I mean.

Can you please tell me the tickness of the expanded metal for the fire box? Thank you

Hey Scott, first those $3.00 thermometers are junk. You can never get a straight reading out of the two. Buy some quality thermometers. Second, your baffles are dumb guy, the bricks pretty good idea because they will help contain heat in the chamber. Back to the baffle, you do know that usually when you buy a char smoker like that the side firebox usually comes with another airflow dampener in case you want to take the firebox off and use it as a small BBQ. Third, Your grate in the firebox, good idea. Fourth, your extension on your outflow tube, Dude get a piece of 10 inch flashing in a roll, Cut about 2 feet of flashing and roll it up. stick it in your outflow or chimney, let go of it and walla you have a very sturdy lowered chimney that you can adjust for different conditions. I went one better and bought a propane three burner char griller. Its a fantastic grill all by itself. But I also got a firebox for it for smoking. Did my mods. Anyone knows that has been smoking for a while, knows that meats will only take the smoke for the first couple hours then any more wood your putting in the firebox is a waste. Money!! I get the smoker grill up to 225 degrees with the propane while my wood is getting ashed up in a chimney starter. Once I get my temp right I'll add the wood and the meats. After I add the wood I will shut the propane off all except one burner that I keep a very low flame. I smoke for people all over the AZ area. Always getting calls from people. This set up works great when doing the extra long smokes. Once you go past the 2 hours the firebox is pretty dead so just adjust the temp by your one burner then go drink one and relax. Use a GPS digital thermometer so you can monitor temps on the smoker and the meats. If you would like some tips, tricks to smoking e-mail me at lakotawolf25@gmail.com have fun and enjoy the smoked meats.

I couldn't help but notice the gas side burner. Where did you get it? BTW, thanks for the vid!

Awesome video. Is the chimney mod necessary if I am not using a smoke box? For now I am doing a couple of beer can chickens for a party. Was planning on putting the fire on the right chickens on the left. Does that make sense?

good video sir.

I see you cut open the opening between the fire box and the smoker itself. How large did you make the opening and how did you cut it open?

Dude, thanks for the video but I'm confused! When I put down baffles on top of brick it's so low that it cuts off almost half of the opening between the smoker and the pit. Are you using oversized bricks or something? what am I missing? Thanks!

great video but how do you get the dryer vent hose to attach to the chimney?

awesome video!!!!

Hi great video. How did you secure the dryer vent hose to the chimney? I just purchased one of these grills.

@nwambe THe post won't all ow me to respond directly so I hope you see this. It would be the same thing and work fine.

Just bought me a char griller minus the burner on the left side, have noticed I lose a lot of smoke around the drum have you done any mods for that or notice that yourself

Scott, Planning to get my 1st grill, what are your thoughts on the Char-Grill gas grill (E3072)?

Hey Scott, where do you find the expanded metal for the fire box grate? Thanks in advance for your help.

What happen to your propane side burner? Does it work

Hey thanks for the video, what size dryer house is that

What is the highest temperature that you can reach on that grill?

Im getting this grill. Can i put charcoal and wood chips in the main part of the grill on one side and a water pan on the other?

I see you used the 550 degree thermometer. There is a 475 degree thermometer that is approx. 5 dollars cheaper. Is there an advantage to the 550 degree thermometer?

Is there a rotisserie upgrade?

So you removed the original ash pan? My grill is very similar to yours...but I sometimes use the main barrel for direct heat (burgers and such)...e.g., I need the ash pan for the charcoal...so I can't install a baffle where you did. But still want to even out the heat within the barrel when smoking. What do you suggest?

you don't soak your wood in water?