In this instructable, I would like to show how to:
1) Remove the fat cap from a picnic ham.
2) Debone a ham.
3) Make a simple Teriyaki Marinade (which I will later turn into a glaze)
4) Tie a picnic ham
5) Soak and package wood chips to smoke the ham
6) BBQ low and slow for about 6 hours until meat is 180 degrees.
What you will need:
A water smoker (or a set up for indirect grilling)
A Picnic Ham ( I used about a 10 lb picnic ham before boning)
A sharp knife
Cotton butchers twine
Charcoal
Large Freezer bag & a bowl to put it in
For the marinade:
10 oz bottle of soy sauce
1/2 Cup Dry Sherry
1/2 Cup white vinegar
1/4 Cup Worcestershire sauce
3 garlic cloves put through a press
2 Tablespoons Onion Powder
To add to the marinade to turn into a glaze:
1/2 Cup ketcup
1/2 Cup sugar
2 Cups of wood chips soaked and made into foil packets (I used Jack Daniels Chips)

Step 1: Combine Marinade Ingredients

In a bowl, combine a 10 oz bottle of say sauce, 1/2 Cup dry sherry, 1/2 Cup vinegar, 1/4 Cup worcestershire sauce, 3 garlic cloves put through a press (or smashed with the side of a knife and completely minced) and 2 Tablespoons of onion powder. Put the marinade on the side while you de-bone the picnic ham.
NOTE: You may be saying that this is going to be way too salty. Don't worry. Unlike a dry rub which contains salt, meat absorbs marinade at a much lower rate. Your wet marinades have to be much stronger than your dry rubs.

Step 2: Taking the Fat Cap Off the Picnic Ham

It will be easier to take the skin and fat cap off if the ham is very cold. If it isn't, put it in the freezer for 10 minutes or so to "firm up" the fat. Please be very careful, and adults only please. One side of the picnic ham will be almost completely covered with a skin. Turn the ham over and you will find that the other side has skin only a few inches on the thin end of the ham. This is the place to begin. Just slice through the skin to start. Make sure your knife is SHARP. Once you make the initial cut, carefully slice between the fat and meat to get a piece of skin to hold onto. More than cutting, you will be pulling the skin and passing the knife in the area between the fat and the meat. When you get to the end, just turn the ham over and continue. Work slowly and carefully. It will take a while when you start this. After you bone out a couple of picnic hams you will get quicker

Step 3: Taking the Bone Out of a Picnic Ham

Start at the thicker end of the ham. Slice down until you hit the bone. Work the knife carefully on either side of the bone until you have taken the meat away from the joint at the end of the ham. See next picture. Use your knife to find the bone and cut along both sides and then detach the meat. Be very careful. If you cut into the meat it isn't a big deal as you will be tying it up after it's marinated, but if you cut yourself...

Step 4: Marinate the Ham

Take the boned ham and put it into a large freezer bag. Put the bag into a bowl that will hold it and pour over the marinade you put on the side earlier. Put the ham in the refrigerator overnight preferably 24 hours ahead because as I said earlier a wet marinade is not absorbed anywhere near as much or as quickly as a dry rub that contains salt. You might ask then why marinate at all. Dry rubs actually take moisture out of the meat whild marinades add it. The reason for the bowl is that this can be a messy operation. I purposely didn't wipe the marinade from the bowl or bag to show the necessity of the bowl. Remember also, bags sometimes leak or open and that would be quite a clean up project.

Step 5: Next Day, Tie Up the Ham

Drain the marinade from the bag into a small pot and reserve. Later we are going to turn this into a glazing sauce. The meat will look a bit pickled at this time. I spread out aluminum foil to tie the ham on as it can still be a bit of a mess. Put the ham fat cap side domn on the foil and roll it up into the same way it was when the bone was in it. Take enough cotton butchers twine to go around the ham and tie it in the middle, See the next picture. I put a total of 4 ties around the roast, and then one the long way making a loop around the origan 4 ties. I then flip the ham over and tie loops around the ties on that side meeting and tying to the place I started. You are now ready to heat your smoker. Leave the ham out until ready to go on.

Step 6: Heat Up Charcoals to Put Into Your Smoker (or Grill)

I put about 32 charcoals on to begin heating. Put hot (preferably Boiling water) into your smoker. When the coals are covered by a white ash, add them to the smoker. When the smoker comes up to heat, put the marinated tied picnic ham on and cover.

Step 7: Wood Chip Foil Packages

I used jack Daniels chips for this. They are chips made from the oak barrels that Jack Daniels is aged in. I love this stuff. You are going to make 4 foil packs of soaked chips. You will be adding 1 every 1/2 hour for the first 2 hours of smoking. You can soak all your chips at once if you like. Put the chips in a bowl and cover with water for at least 30 minutes before putting on the smoker. Take a 1 foot sqare (or larger) of aluminum foil and put the chips in the middle. Fold into a package and make several holes in the top side to let the smoke escape. You put the packs directly on the hot coals so they produce smoke.

Step 8: Turn the Marinade Into a Teriyaki Glaze

Now that you have your ham on the smoker, turn your attention to the reserved marinade. Put the small pot with the reserved marinade and add 1/2 Cup Ketcup and 1/2 Cup sugar. Put it on to boil and reduce until it's a glaze. It took me 15 minutes to reduce. See the next picture. When the bubbles look like this, small and furious, it's done. Turn it off.

Step 9: Keep the Heat at 220-225 Degrees

I have a picture of the top of my smoker. There are no tempperatures, only a warm, ideal, and hot divisions. From experience (and putting my instant read thermometer in the side of the smoker) I know this is where 225 is. I am aiming for a finished Picnic Ham at 180 degrees. The next picture is of the ham after 2 hours of the oak smoke.

Step 10: This Picture Is of the Ham After 4 Hours of Cooking.

I started with a 10 Lb ham. I removed the fat cap, and the bone. The ham after this weighed approximately 7 Lbs. I started basting the ham with the ham with the Teriyaki glaze after 5 1/2 hours. I put it on every 1/2 hour. The Picnic Ham reached the 180 degree mark in 6 1/2 hours. Because the times are so variable I definitely recommend an instant read thermometer, or better yet, a probe thermometer that keeps constant temperature readings.

Step 11: At 180 Degrees Plate, Cover With Aluminum, and Let It Rest

This ham will be plenty juicy, but let it be all it can be. Put it on a plate and cover with aluminum foil and let it rest for 20-30 minutes before slicing.
I hope this instructable is understandable. If you prefer, you can leave the bone in, but try to bone it out. Impress your friends. It really is nice to just slice the ham when it's done, rather than slicing the meat off the bone.