How To Turn A Gas Bbq Into A Charcoal Grill
Gas grills are incredibly convenient, but sometimes you crave that rich, smoky flavor that only charcoal can create. The good news is—you can safely and effectively turn a gas BBQ into a charcoal grill with just a few adjustments.
Before You Begin: Safety First
Not every gas grill is designed to handle charcoal heat. Before starting:
Check the manufacturer’s manual. Some gas grills prohibit charcoal use because it can damage internal components.
Do not use charcoal over active gas burners. Always remove or shield gas components first.
Avoid lighting charcoal with gas. It can cause flare-ups and warp the burner tubes.
Keep a fire extinguisher nearby whenever working with open flame or solid fuel.
If your grill is not convertible, consider using a charcoal tray insert or hybrid grill system, like those made by TopGrill Outdoor, which safely combine both fuel types.
Tools and Materials You’ll Need
| Item | Purpose |
|---|---|
| Charcoal (lump or briquettes) | Main fuel source |
| Charcoal tray or smoker box | Holds charcoal above burners |
| Heat-resistant gloves | Safety |
| Tongs and grill brush | Handling and cleanup |
| Aluminum foil | Protects burners and interior |
| Chimney starter | For lighting charcoal evenly |
Step-by-Step: Converting Your Gas Grill
Step 1: Disconnect the Gas Supply
Turn off the gas valve completely and disconnect the propane tank or natural gas line.
Make sure all knobs are in the OFF position.
Remove the gas tank from the area for safety.
Never leave gas connected while using charcoal—it poses a fire and explosion risk.
Step 2: Remove Grates and Flame Tamers
Lift off the cooking grates and flame tamers (metal shields above the burners).
This exposes the burner tubes beneath.
Brush off any grease or debris with a wire brush to prevent unwanted fires.
Step 3: Protect the Burners
Cover the burner tubes and ignition system with heavy-duty aluminum foil to protect them from falling embers and intense heat.
Alternatively, remove the burners entirely (if your grill allows easy removal).
Some users place a metal baking sheet or stainless steel plate over burners for extra protection.
On premium models like TopGrill Outdoor gas systems, the burner compartments are removable, allowing safer hybrid conversions.
Step 4: Add a Charcoal Tray or Layer
Place a charcoal tray insert or metal smoker box inside the grill body, above the burners.
If you don’t have one, you can use a stainless steel roasting pan or metal basket to hold the charcoal safely.
The goal: keep charcoal off direct contact with burner tubes and maintain airflow.
Some aftermarket kits (like Weber or Char-Broil) sell charcoal conversion trays that fit most gas grill models.
Step 5: Add and Light Charcoal
Fill the tray or pan with enough charcoal to cover the bottom evenly (1–2 layers).
Use a chimney starter to pre-light charcoal until the coals turn grayish-white.
Carefully pour the lit charcoal into the tray.
Spread evenly for consistent heat.
Avoid lighter fluid inside a gas grill—it can damage coatings and leave chemical residue.
Step 6: Replace Cooking Grates
Once charcoal is glowing and stable, replace your grill grates.
Close the lid to preheat the grill for about 10 minutes before cooking.
Adjust vents or lid position (if available) to regulate heat.
You’ve now effectively turned your gas BBQ into a traditional charcoal grill.
Managing Heat Like a Pro
| Cooking Style | Charcoal Setup | Temp Range |
|---|---|---|
| Direct Grilling | Even layer under the grate | 400–500°F (200–260°C) |
| Indirect Grilling | Coals on one side only | 300–375°F (150–190°C) |
| Smoking | Small pile + wood chunks | 225–275°F (110–135°C) |
Adjust heat by raising or lowering vents (if your lid has them).
For gas grills without vents, open the lid slightly or use fewer coals to reduce temperature.
Cleanup
Let the charcoal burn out completely after cooking.
Once cool, remove ashes using a metal scoop or vacuum.
Discard ashes in a metal container — never in plastic or paper bins.
Wipe down interior surfaces and remove the foil from burners.
Reattach your gas system only after everything has cooled and been cleaned.
Regular cleaning prevents corrosion and ensures your gas burners stay functional.
Pro Tips from Outdoor Cooking Experts
Add wood chips or chunks for a smoky flavor boost.
Use lump charcoal instead of briquettes for higher heat and cleaner flavor.
Place a drip pan below fatty meats to prevent flare-ups.
After cooking, brush the grates while still warm to remove residue easily.
✅ Summary
| Step | Action | Key Tip |
|---|---|---|
| 1 | Disconnect gas supply | Never use gas and charcoal together |
| 2 | Remove grates & protect burners | Prevent heat damage |
| 3 | Add charcoal tray or pan | Keeps coals off gas components |
| 4 | Light charcoal safely | Use chimney starter |
| 5 | Cook with lid closed | Controls temperature and smoke |
| 6 | Clean and reassemble | Reconnect gas only after cooling |
Final Thoughts
Converting your gas BBQ into a charcoal grill gives you the best of both worlds — convenience when you need quick cooking, and smoky flavor when you want authentic barbecue results.
TopGrill Outdoor’s dual-fuel systems are engineered for this flexibility, featuring interchangeable burner trays and charcoal drawers that let you switch between gas and charcoal safely in minutes — bringing true versatility to every outdoor chef.