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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. The Shipping Box
These photos show the exterior of the 22-1/2" Weber Smokey Mountain Cooker box. To learn more about current and past versions of WSM box art, visit WSM Box Art. In Photo 4, 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 5 shows that the WSM is "Made in USA". 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 facing 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
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 an x-shaped piece of cardboard that supports the weight of the grates (Photo 8). Layer 2: Middle Cooking Section
Removing the 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 9-10). Removing these boxes reveals the top of the charcoal bowl at the bottom of the box covered with bubble wrap (Photo 11). Removing the middle cooking section and bubble wrap reveals another molded pulp separator positioned over the charcoal bowl (Photo 12). The small cardboard box contains the legs, grate support brackets, nuts, bolts, washers, and owner's manual (Photo 13). The eight-sided box contains the heat shield wrapped in paper (Photos 14-15), the charcoal chamber (Photo 16), and the water pan (Photos 17). 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 18) and shipped in place, fastened to the side of the middle cooking section. Layer 3: Charcoal Bowl
Removing the second molded pulp separator fully reveals the third layer葉he charcoal bowl layer (Photo 19). 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
Removing the charcoal bowl and the third molded pulp separator reveals the fourth and final layer葉he lid layer (Photo 20). It consists of the lid, a fourth and final pulp separator, 4 more cardboard pieces, and the vinyl cover hiding under the lid (Photo 21). WSM Packaging - 2008 & Earlier The Shipping Box
These photos show the exterior of the Weber Smokey Mountain Cooker box. To learn more about current and past versions of WSM box art, visit WSM Box Art. In Photo 24, 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. The Charcoal Bowl Layer
These photos show the contents of the first layer葉he charcoal bowl layer. Photo 25 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 26). Removing the vinyl cover reveals the water pan resting in a sheet of protective bubble wrap (Photo 27). With the water pan and bubble wrap removed, the charcoal bowl is now exposed and ready to be removed from the box (Photo 28). 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 29). The Lid Layer
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 30). The charcoal chamber sits on a round disc of cardboard placed inside the lid (Photo 31). With the cardboard disc removed, the lid is now exposed and ready to be removed from the box (Photo 32). 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 33). The Middle Cooking Section Layer
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 34). 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 35). The Grates Layer
Removing the third cardboard insert reveals the fourth and final layer葉he grates layer (Photo 36). 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. 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 MaterialsVirtually 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. |
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