Like throngs of others backyard bar-b-quer's, I wanted to get a bit more smoke flavor on my gas grill without purchasing a full on smoker. One day I'm sure I'll have a proper smoker, but for right now I'm simply just not at that scale or scope. To improve my situation in the mean time, I built a very simple wood chip tray that was custom sized to my Weber BBQ.
The easy to make, cost effective smoker tray that I bent into shape in minutes from some sheet metal serves my casual rib making needs very well and couldn't be simpler to use. While it's no custom full fledge meat smoker, it does make A LOT of smoke and help me turn out one of my favorite foods - BBQ ribs.
Step 1: Design a Metal Tray
I measured my grill's width and the height between the flavor bars and grill grate and took those measurements to the shop.
The goal was to create a simple metal reusable tray that would hold wood chips above the bbq flame element in order to create smoke.
I used some old sheet metal to create the chip tray. Mark the dimensions of the box, in my case 20" wide x 4" deep x 1 1/2" tall. 1 1/2" is about the max height that the tray can be so that it still fits underneath the grill grates and 20" is the width of the interior of my grill.
The sheet metal will be folded up just like a cardboard box, so mark the bottom of the tray and the four walls. The four 1 1/2" corners that remain will be cut off.