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WSM Unboxed

Originally posted: 08/01/2001
Last updated: 09/26/2014

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Here's a look at how the Weber Smokey Mountain Cooker is packaged for shipping and the "out of box" experience you'll have when unpacking it.

Click on any of the photos to view a larger image.


2009-Present 18-1/2" Packaging

Out Of Box Video

Here's a short video that shows the out of box experience for the 18-1/2" Weber Smokey Mountain Cooker.

The Shipping Box

18-1/2" WSM box
Photo 1
Side view of box
Photo 2
Weber website URL on top of box
Photo 3
18-1/2" model number label
Photo 4
Close-up of Made in USA text
Photo 5
Close-up of Free Cover text
Photo 6
       

These photos show the exterior of the 18-1/2" Weber Smokey Mountain Cooker box. To see photos of past versions of the WSM box, visit WSM Box Art.

Photo 1 shows the front of the box featuring small and large photos of the cooker. Photo 2 shows the side of the box. In 13 languages it says:

  • 480 sq inch total cooking surface
  • Two 18-1/2" diameter cooking grates
  • Built-in thermometer
  • Porcelain-enameled bowl and lid
  • Large water pan

Photo 3 shows the Weber website URL on the top of the box. In Photo 4, the number "721001" is the cooker's model number. The fine print at the bottom of the label indicates that the box measures 21.3" x 21.3" x 31.3" and has a shipping weight of 47 pounds.

Photo 5 shows that the WSM is "Made in USA, incorporating globally sourced component parts". Photo 6 shows that a free vinyl cover is included with the cooker.

The box is made of corrugated fiberboard with single wall construction. The top and bottom flaps are sealed with 6" wide plastic packing tape; no staples or adhesives are used.

Upon opening the box, you discover that the Weber Smokey Mountain Cooker is broken down into pieces that are packed vertically in four layers.

Here's an interesting bit of trivia about how WSM boxes are packed at the factory. The top of the box is sealed and placed upside down, then parts are loaded in from the bottom end of the box. The box is sealed and turned right-side up, so what was on the bottom at the factory is now on the top when you unpack your new WSM at home.

Layer 1: Grates

Charcoal grate and cooking grates
Photo 7
Grates removed
Photo 8
     

These photos show the contents of the first layer葉he grates layer (Photo 7). The charcoal grate is on top, followed by the bottom cooking grate, and finally the top cooking grate. Beneath the grates is the first of 4 molded paper pulp separators and two cardboard boxes that supports the weight of the grates (Photo 8).

Layer 2: Middle Cooking Section

Middle cooking section layer
Photo 9
Small cardboard box removed
Photo 10
Eight-sided box removed
Photo 11
Middle cooking section removed
Photo 12
Legs, grate support straps, hardware pack, and owner's manual
Photo 13
Heat shield
Photo 14
Water pan
Photo 15
Charcoal chamber
Photo 16
Access door
Photo 17
 

Removing the first molded pulp separator brings us to the second layer葉he middle cooking section layer. Inside the middle cooking section is a small cardboard box and an an eight-sided box (Photos 9-10). Removing these boxes reveals the top of the charcoal bowl at the bottom of the box (Photo 11). Removing the middle cooking section reveals another molded pulp separator positioned over the charcoal bowl (Photo 12).

The small cardboard box contains the legs, grill straps, nuts, bolts, washers, lid handle, and owner's manual (Photo 13).

The eight-sided box contains the heat shield wrapped in plastic (Photo 14), the water pan (Photo 15), and the charcoal chamber (Photo 16). The water pan sits on a piece of bubble wrap inside the charcoal chamber.

The access door is wrapped in a plastic bag (Photo 17) and shipped in place, fastened to the side of the middle cooking section.

Layer 3: Charcoal Bowl

Charcoal bowl layer
Photo 18
       

Removing the second molded pulp separator fully reveals the third layer葉he charcoal bowl layer (Photo 18). It consists of the charcoal bowl and a third molded pulp separator that help support the weight of the middle cooking section and all the component parts above.

Layer 4: Lid

Lid layer
Photo 19
Vinyl cover
Photo 20
     

Removing the charcoal bowl and the third molded pulp separator reveals the fourth and final layer葉he lid layer (Photo 19). It consists of the lid, a fourth and final pulp separator, and the vinyl cover hiding under the lid (Photo 20).

Due to the lack of clearance between the charcoal bowl and lid, the lid is shipped without the lid handle in place. You'll find the handle in the small cardboard box with the other parts and fasteners.


2009-Present 22-1/2" Packaging

Out Of Box Video

Here's a short video that shows the out of box experience for the 22-1/2" Weber Smokey Mountain Cooker.

The Shipping Box

22-1/2" WSM box
Photo 21
Side view of box
Photo 22
Close-up of box text
Photo 23
22-1/2" model number label
Photo 24
Close-up of Made in USA text
Photo 25
Close-up of Free Cover text
Photo 26
       

These photos show the exterior of the 22-1/2" Weber Smokey Mountain Cooker box. To see photos of past versions of the WSM box, visit WSM Box Art.

Photo 21 shows the front of the box featuring small and large photos of the cooker. Photos 22-23 shows the side of the box. In 13 languages it says:

  • 726 sq inch total cooking surface
  • Two 22-1/2" diameter cooking grates
  • Built-in thermometer
  • Porcelain-enameled bowl and lid
  • Large water pan

In Photo 24, the number "731001" is the cooker's model number. The fine print at the bottom of the label indicates that the box measures 26.5" x 26.5" x 34" and has a shipping weight of 68 pounds.

Photo 25 shows that the WSM is "Made in USA". Photo 26 shows that a free vinyl cover is included with the cooker.

The box is made of corrugated fiberboard with single wall construction. The top and bottom flaps are sealed with 6" wide plastic packing tape; no staples or adhesives are used.

Upon opening the box, you discover that the Weber Smokey Mountain Cooker is broken down into pieces that are packed vertically in four layers.

Here's an interesting bit of trivia about how WSM boxes are packed at the factory. The top of the box is sealed and placed upside down, then parts are loaded in from the bottom end of the box. The box is sealed and turned right-side up, so what was on the bottom at the factory is now on the top when you unpack your new WSM at home.

Layer 1: Grates

Charcoal grate and cooking grates
Photo 27
Grates removed
Photo 28
     

These photos show the contents of the first layer葉he grates layer (Photo 27). The charcoal grate is on top, followed by the bottom cooking grate, and finally the top cooking grate. Beneath the grates is the first of 4 molded paper pulp separators, an x-shaped piece of cardboard, and two cardboard boxes that support the weight of the grates (Photo 28).

Layer 2: Middle Cooking Section

Middle cooking section layer
Photo 29
Small cardboard box removed
Photo 30
Eight-sided box removed
Photo 31
Middle cooking section removed
Photo 32
Legs, grate support straps, hardware pack, and owner's manual
Photo 33
Heat shield wrapped in paper
Photo 34
Heat shield unwrapped
Photo 35
Charcoal chamber
Photo 36
Water pan
Photo 37
Access door
Photo 38

Removing the first molded pulp separator and x-shaped cardboard brings us to the second layer葉he middle cooking section layer. Inside the middle cooking section is a small cardboard box and an an eight-sided box (Photos 29-30). Removing these boxes reveals the top of the charcoal bowl at the bottom of the box covered with bubble wrap (Photo 31). Removing the middle cooking section and bubble wrap reveals another molded pulp separator positioned over the charcoal bowl (Photo 32).

The small cardboard box contains the legs, grate support brackets, nuts, bolts, washers, and owner's manual (Photo 33).

The eight-sided box contains the heat shield wrapped in paper (Photos 34-35), the charcoal chamber (Photo 36), and the water pan (Photos 37). The charcoal chamber sits on a piece of bubble wrap inside of the water pan.

The access door is wrapped in a plastic bag (Photo 38) and shipped in place, fastened to the side of the middle cooking section.

Layer 3: Charcoal Bowl

Charcoal bowl layer
Photo 39
       

Removing the second molded pulp separator fully reveals the third layer葉he charcoal bowl layer (Photo 39). It consists of the charcoal bowl, a third molded pulp separator and 4 cardboard pieces that help support the weight of the middle cooking section and all the component parts above.

Layer 4: Lid

Lid layer
Photo 40
Vinyl cover
Photo 41
     

Removing the charcoal bowl and the third molded pulp separator reveals the fourth and final layer葉he lid layer (Photo 40). It consists of the lid, a fourth and final pulp separator, 4 more cardboard pieces, and the vinyl cover hiding under the lid (Photo 41).


2008 & Earlier Packaging

The Shipping Box

Exterior view of box
Photo 42
View of box label
Photo 43
Label including model number & box specs
Photo 44
   

These photos show the exterior of the Weber Smokey Mountain Cooker box. To see photos of past versions of the WSM box, visit WSM Box Art.

In Photo 44, the number "2820" is the cooker's model number. The fine print at the bottom of the label indicates that the box measures 20.5" x 20.5" x 28.2" and has a shipping weight of 48 pounds.

The box is made of corrugated fiberboard with single wall construction. The top and bottom flaps are sealed with ordinary packing tape; no staples or adhesives are used.

Upon opening the box, you discover that the Weber Smokey Mountain Cooker is broken down into pieces that are packed vertically in four layers. Each layer is described below.

Layer 1: Charcoal Bowl

Hardware box
Photo 45
Vinyl cover
Photo 46
Water pan
Photo 47
Charcoal bowl
Photo 48
Cardboard insert
Photo 49

These photos show the contents of the first layer葉he charcoal bowl layer. Photo 45 shows what you see when you first open the box. A small sealed cardboard box holds the owner's manual, access door and a brown paper bag containing the legs, grate support brackets, nuts, bolts and washers.

Removing the hardware box reveals the vinyl cover, folded neatly into a square and sealed in plastic (Photo 46).

Removing the vinyl cover reveals the water pan resting in a sheet of protective bubble wrap (Photo 47).

With the water pan and bubble wrap removed, the charcoal bowl is now exposed and ready to be removed from the box (Photo 48).

Finally, a square cardboard insert separates and protects the charcoal bowl from the layer below. The hole in the middle of the insert has a series of cuts around the perimeter that conform to the shape of the charcoal bowl (Photo 49).

Layer 2: Lid

Charcoal chambe
Photo 50
Cardboard insert
Photo 51
Lid
Photo 52
 Cardboard insert
Photo 53
 

With the cardboard insert removed, we proceed to the second layer葉he lid layer. This layer begins with the charcoal chamber wrapped in protective bubble wrap (Photo 50).

The charcoal chamber sits on a round disc of cardboard placed inside the lid (Photo 51).

With the cardboard disc removed, the lid is now exposed and ready to be removed from the box (Photo 52).

This layer also has a square cardboard insert that separates the lid from the layer below. This insert has a larger hole in the middle and similar, but shorter, cuts around the perimeter (Photo 53).

Layer 3: Middle Cooking Section

Middle cooking section
Photo 54
Cardboard insert
Photo 55
     

After removing the second cardboard insert, we proceed to the third layer葉he middle cooking section layer. This layer contains only the middle cooking section sitting on what appears to be the bottom of the box (Photo 54). However, removing the section reveals that the top cooking grate handles are sticking out of a cardboard insert at the bottom of the box (Photo 55).

Layer 4: Grates

Cooking grates & charcoal grate
Photo 56
       

Removing the third cardboard insert reveals the fourth and final layer葉he grates layer (Photo 56). The charcoal grate is placed on the top cooking grate, and the bottom cooking grate is slipped over the top grate's handles, making a nice, neat package.


Packaging Improvements In 2009

Prior to 2009, WSM packaging left something to be desired. It was fine for shipping the product from the factory to retail stores, but it just couldn't stand up to rigors of UPS or FedEx shipping. The materials weren't strong enough and the packaging design wasn't quite right. Sometimes the packing tape that sealed the box would fail. If the box was dropped during shipping, the stacked parts would compress into one another, tearing the cardboard separators between layers. The edges around the top of the box were susceptible to crushing, resulting in damage to the charcoal bowl.

Today, WSM packaging is more substantial and better designed to protect parts during shipping, even if the box is dropped or shipped on its side.

When buying a Weber Bullet from a retail store, examine the condition of the box before taking it home. If you see any crush marks or holes, open the box and check the contents.

When buying from an online retailer, check the condition of the box upon delivery and have the carrier note any major damage in their records. Check the contents carefully for any damaged or missing parts.

If you find any dents or damaged porcelain finish or you're missing a part, your best bet is to contact Weber Customer Service directly at 800-446-1071. Weber is quick to replace any damaged or missing parts free of charge, and it's much faster than contacting your online retailer or shipping company.

See Parts Troubleshooting for problem areas to look for as you unpack and assemble a new Weber Bullet.

Recycling The Packing Materials

Virtually all WSM packaging is recyclable or reusable. The cardboard, molded pulp separators, and paper can be recycled. The bubble wrap can be saved and reused when shipping other packages. The plastic bag covering the access door can be recycled in some communities.

The packaging does not indicate what percentage of the material is made from pre- or post-consumer recycled materials.

Back to WSM Product Information

 
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