Ok...so here's the photoplay of how it all went down...
So I'm expecting a big outdoor, open pit/grill scenario, and when I get there, it's inside the shelter, and it's this hearth/oven type setup:
The middle rack is right between the upper doors and bottom doors. And this thing is a mess:
And there are ashes accumulated past the bottom doors, almost all the way to the middle rack:
So I spent most of the Friday night trying to wash off the grates, and shoveling as much ash as I could out of the pit. I shoveled out an entire garbage can full before I hit a layer where it was compacted solid. I wasn't going to try to smash it up, so that was going to be good enough. But that remaining ash pretty much decided for me that I would need the fuel on the middle rack, not in the bottom of the pit.
The racks were just too disgusting to cook directly on (and I'm not all that squeamish about that) so I had to foil the racks. This looks like the foil is solid, but I did break it through between the grates.
Now, the Major Screwup #1 is that I bought "heavy duty" foil when I saw it at the dollar store, when I ran in to pick up some cheap tongs. Turns out, not unexpectedly, that it is thinner than the foil around a stick of juicy fruit. That became a major problem later.
So we put the butts on the racks and covered with a hood of foil.
So here's Major Screwup #2, the most crucial one. My original plan was to have the butts on that right side, and have a moderate fire on the left side, to cook the butts indirectly. With the design of the cooker, I wasn't sure if the chamber would heat enough to make that happen. And as happens so much with barbecue screwups, impatience was the enemy. I was unhappy with how the chamber just wasn't heating up, and assumed that the design wouldn't let it. In reality, at 5am, the brick structure was ice cold, and probably needed 1-2 hours to warm up.
The first response was to build the fire on the left side bigger, and then when that didn't do it, to put the coals under the butts directly to have it over a low-moderate direct heat. The end result was exactly what I didn't wan't...over high direct heat:
Obviously, you can see the problem there. I would have been ok with a fire that hot offset, or over direct heat with a very small fire, but that was the worst of both worlds. And with the design, there's almost nothing you can do to bring the fire down...you just have to let it burn out. I was able to move some coals to the other side and reduce the direct heat somewhat, but not very much.
I did pretty good with the smoke. Two techniques worked pretty decent. Either wrapping the hickory logs in foil and punching holes in it, and putting it in the fire directly, or putting it unfoiled in the fire until it caught, tamping out the flames, and moving it into the lower chamber to smolder. I used variations of both techniques depending on what kind of fire I had going.
Which was another problem. The guy supplying the charcoal brought three bags of Rockwood. When I first saw that, my heart soared...I used Rockwood for a while and it showed that he know what he was doing. But then it sank a bit, when I remembered why I stopped buying Rockwood...I got a couple bags of chips and dust, and I'm not about $35 bags of chips and dust. Unfortunately, these bags were terrible...95% chips and dust...I would never recommend Rockwood after that. I was spending the whole day shovelling chips into the fire, trying to keep it from going out, but not get too hot. If I'd just had a decent bag of lump with some big chunks/logs that would burn evenly for a while, that would have gone a long way.
At this point, I knew we needed a couple things. I needed some real heavy foil to wrap these in, because they'd be done earlier than planned, and I'd need that for the ribs, and I needed something to be able to grill the chicken on because these wide grates weren't going to cut it. So I headed off for the nearest Walmart 35 minutes away (actually across the GA border into Alabama) and got some real foil, and some cheap mesh grill topper type deals.
So anyway, I got back, and despite my best efforts, low and slow became high and fast...I'd blasted right on through the stall at about 5-6 hours...
The temperatures were headed past 200 at this point...I insisted we had to take them off and just hope to hold them if we wanted something edible at all. And you can see what the direct heat did to the bottom part of the butt. There was what appeared to be a good half inch+ of completely burned, inedible charcoalized layer on each one. And here is where that damn foil got me. The guy that provided the butts put his own rub on them, all really sweet stuff (Honey, Lemon Pepper, Pecan...WTF, really?), which was a nightmare for direct heat obviously. And it melded to the damn foil, and the foil being so light it was nearly impossible to get off. So I spent about 30 minutes just trying to pick the foil off the bottoms of these butts so I could wrap them and put them in a cooler. I was really upset at myself at this point. I was figuring on the bottom 25% of each butt would have to be shaved off, just to get to some dry meat you could eat. We wrapped them up tight with heavy duty foil and stacked them in a gatorade style cooler to hold.
Out came the ribs. Before I left, I had grabbed a bag of rub from the freezer, left over from the last cook I did about a month ago. And fortunately, the guy that brought the meet thankfully forgot his rub, so I was able to use mine without a fight. He probably had some peanut butter and jelly rub in mind or some nonsense. So I grabbed some mustard and we layed down my rub on the ribs. You can see those grill topper things I bought.
So this is the way way I decided to tackle the ribs. Because the ribs would cover the whole surface, indirect wasn't an option. So I was going to need to cook directly, over as low a fire as I could reasonably maintain with chips of lump. So I covered all the grates with heavy duty foil, and went about poking numerous holes to let smoke through. Then I laid the grill toppers on top of the foil, oiled them, and laid out the ribs.
And then I covered them loosely with another row of foil...somehow I missed getting a picture of them with the foil over them or what they looked like at the end. They went for about five hours, with me applying smoke for the first couple hours and then just trying to maintain temperatures hot enough to cook them but not to burn them. Pulled them and foiled them to hold them. By this point I had other guys start the process of pulling the pork butts and chopping the ribs, because I had chicken to do.
I had insisted right up front before we went to be able to do my own chicken. I've got an awesome marinade that kills it for bone in grilled chicken, and if I was going to try to draw a line somewhere, it was going to be about that. So Friday morning before we left I'd whipped up about a gallon, and Saturday morning after we got the butts on, I'd put all the chicken in my marinade for about 8 hours.
I left the same foil covering I'd had for the ribs, and just put another layer of the grill toppers and oiled them up real good. At least now we were flat out grilling, not playing around with any low and slow, so I knew this could turn out great, but it was still going to be a challenge, it was 76 or so legs and thigh to do all at the same time...
I even managed to make enough room for another guy to jump in and make some vegetables..
And of everything...I rocked the chicken...even managing all those pieces at once, and dealing with those cruddy grill toppers, I lost the skin on ONE piece...everything else, skin was brown, crispy and intact...
I knew that at least, no matter what, the chicken would be good.
So I finally can turn to see how the pork prep is going.
Hmmm...that doesn't look all that bad...
Turns out the resting had softened the burned edges enough to just chop them up and mix them in. I didn't get a good picture before it was pulled, but I had a pretty nice smoke ring...you can see a bit of it on a few shreds here...
So that looks like it might be about edible... how about the ribs?
Hmm...not bad at all...not falling off the bone, but biting off clean...did I actually nail the ribs?
On the table...here's all the food...front three are all pulled pork. In the back row, two full trays of ribs cut up, and the back right tray is piled up chicken...these are turkey cooking sized pans...
People lost their minds over it. Couldn't stop talking about how great it was. When we arrived back yesterday, the adults split the leftovers up between them. As I mentioned yesterday, the ribs and chicken were pretty good, and the pulled pork was surprisingly ok. Considering the volume of food I was dealing with and the cooking space and the lousy charcoal, I probably couldn't have done much better. Basically, it shows that pork products are pretty damn forgiving and if you can get them to the right temperature you're going to end up with something pretty edible.