Terra Cotta Smoker

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Chicken thighs smoked over rosemary sprigs

I built myself a small ceramic smoker out of unglazed terra cotta flowerpots and have been using it frequently for several months now, it's high time I wrote it up so others can enjoy the smokey goodness and continue to improve the design.

It is based on the smoker Alton Brown built in the Good Eats episode Q which has also been written up here, there and yonder, but I reworked it to use charcoal instead of an electric hot-plate.

Cast of Characters

From left to right:

• Chimney starter of natural hardwood lump charcoal
• Terra cotta feet to allow air under the smoker
• Drilled unglazed terra cotta saucer, inverted to elevate the "firebox" from the floor of the smoker and improve air-flow
• 8-inch unglazed terra cotta orchid pot for the firebox (despite cracking during its first fire, it has held up remarkably well)
• 16-inch unglazed terra cotta pot, fitted with a damper to control air flow (see below)
• Replacement grate for a 14-inch grill (~13.75 inches in diameter)
• 16-inch unglazed terra cotta cactus bowl, fitted with a handle, damper and 1/8th inch hole for a thermometer probe (see below)

The modifications for burning charcoal required a number of holes to be drilled for hardware, probe thermometer and air-flow.  This is actually quite easy, just keep pouring water on the drill site (the terra cotta soaks it up like a sponge) and keep the pressure gentile and the bit true.

Masonry drill bits are my friends

For the top, I built a handle out of scrap wood and thin aluminum bar stock and a damper out of wider (2-inch) aluminum stock; I also added a 1/8th inch hole about halfway down the side for an instant-read thermometer so I can monitor the smoking temperature.

I also added a damper to the bottom, controlling the internal temperature really does require both.

The handle and dampers are attached using stainless steel machine screws, washers and nuts.

I still need to get some fireplace gasket to seal the crack between the body and the top, but it's not critical.

So far, I think the best thing I've made is a 10-hour boston butt (pork shoulder) using only the smokey flavor of the natural hardwood charcoal, though I'll definitely brine it first next time and maybe smoke it over corn cobs.  Rosemary sprigs make a really nice smoke for chicken or lamb.

I think I'll try doing a pot roast tonight...

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