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You should keep in mind that this is not an expensive grill. It's really pretty darn cheap, so you can't expect a beautiful piece of furniture. So ignore the cosmetic defects. I bought it because other reviews made it sound functional, and that's what I care about. First, regarding the size of the grilling surface: The wire shelf does NOT come with it; it's an accessory for which you pay extra. The actual measurements, done with a measuring stick after assembly are: For the main grill: 19.5"x27"=526.5sq"(3.66sq'), of which only about 337.5sq"(2.34sq') are 100% directly above the coals, but that's still a lot. (As a comparison, a standard Weber 22" grill has about 254sq"(1.77sq') that are 100% directly above the coals.) For the side fire box grill: 14.25"x16.5"=235sq"(1.63sq'), of which about 190sq"(1.32sq') are 100% directly above the coals. We plan to try just the side box for grilling when we're making one meal for just the two of us. (EDIT: We have tried just using the side box for grilling a couple of steaks. It works great for that.) I'm going to write this review in stages, editing as I go along. First Stage: Assembly. 3.5 stars. The manual says you need two people to assemble this grill, but nowhere does it give an instruction that requires two people to carry out. I'm a 65-year-old, retired, pencil-pushing male and I had no trouble building this thing by myself in two hours, from ripping open the box to done. I'd say that a strong woman or a man of average strength would have little trouble with the assembly, from a physical standpoint. One serious tip: Do not try to assemble this thing in the hot sun--the black metal gets finger-burning hot. If you follow the instruction manual carefully, doing things in the order given, you shouldn't have a serious problem--IF you also are mechanically inclined or have good common sense. When you buy this griller-smoker model WITH the side box, there is NO side panel to knock out when attaching the side fire box like that other reviewer had to deal with back in 2006, so follow the directions in order. The difficulty is that the instruction manual usually tells you to use the correct bolt--but sometimes it doesn't. In one place it has you threading a 2-inch spacer onto a 1.5-inch bolt, then putting a nut on the bolt. Can't be done, but that's not a problem because in reality the spacer is shorter than the bolt provided. In another place it eventually becomes clear that the grill has been redesigned since the manual was written and one entire numbered assembly instruction should be ignored. Also, they write as if it doesn't matter which side of each wheel is positioned against the leg, but it does. They tell you to "finger-tighten" the nuts on the bolts until you get it completely assembled, but that's still too tight. You need to put the nuts on "finger-loose" or you'll never get it all together. Then there's the place where the text tells you to position the grill "upright" but what they really mean is "on end." (Fortunately, the picture is correct.) There were no missing parts, in fact there were a few extra nuts and bolts. They say you need only a pair of pliers and a 7/16" nut driver, and that's true, but you might want to replace the pliers with a 7/16" open or closed-end wrench. I also bought the Char-Griller Rotisserie accessory, and that has its own problems with the instruction manual. Mainly: The manual text tells you to put the spit collar on the spit rod, but doesn't say which side facing which way. If you put the collar on the way the manual picture shows, there's nothing to keep the other end of the rotating spit rod from slipping out of the motor housing. It just slides in there, there's no click-fit, so it slides out easily during rotating when you don't want it do. But if you put the collar on the spit rod opposite to the picture, the spit collar's contact with the spit bracket will keep the other end of the spit rod from sliding out of the motor housing. The lid won't close all the way that way, though, until you bend the spit bracket out about a 1/4 inch, which is easy enough to do. Now the spit rod stays rotating inside the motor housing, no slipping out. In the end, patience and good common sense ruled, all of these assembly difficulties were overcome, and these are now all problems of the past.

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Second Stage: Seasoning the Grill. 5 stars. Seasoning according to the directions involves painting all surfaces of the grill interior surfaces with vegetable oil (soy oil) including the grills, grates, ash pans, and inside of the lids. Didn't skip anything. Stoked it up and let it get to about 250 degrees F. I even painted the outside of the grill with the oil as it was heating up, which the manual gives as an option. So, in essence, I oiled up every inch of the metal, inside and out, and let it cook for two hours. The grills seasoned perfectly and the exterior surfaces even look much better. The cosmetic flaws in the paint disappeared with the cooking oil treatment. It was now a beautiful shiny deep black and ready to go. Third Stage: Direct Grilling. 5 stars. I butterflied a nearly 5 lb. chicken, marinated it, and put it on the main grill directly over 24 charcoal briquettes and a few pieces of mesquite with the charcoal grate as far down at it would go. I used a Williams-Sonoma remote digital thermometer to monitor the temperature in the thigh meat. When it reached 185 degrees--which took only about a half hour--I took it off. Tender and juicy with a great smokey flavor. Next time I direct-grill a chicken like this, I'll try only 12 charcoal briquettes, and let it cook longer. But I also will be smoking a chicken over indirect heat and will report back on that, too. Other reviewers complained that this thing leaks smoke, but that's not important. (One reviewer--she didn't say what color her hair was--complained that while she was using the grill, the wind blew smoke out of the smoke stack into her face. Guess what the solution to that is. She couldn't.) The lid obviously was never designed to be air tight--I can get all my fingers under the lid at the left end of the barrel when the lid is seated on the bottom. If you open the smoke stack fully, almost all the smoke will pour out of it. If you close off the smoke stack completely, there will be a steady stream of smoke escaping from under the lid. If you think this means your meat isn't getting well smoked, just go over and fling the lid up and then duck because a huge, dense, cloud of smoke will come billowing out at you. That meat is getting drowned in smoke. Fourth Stage: Indirect Rotisserie Smoking. 5 stars. I had ordered a second set of forks for the rotisserie, so I was able to smoke two rotisserie chickens at a time. While that was happening, I noticed that I had plenty of room left on the spit for a third chicken, so I ordered a third set of forks. I have since rotisseried three chickens simultaneously over indirect heat (i.e., from coals in the sidebox only)--each chicken marinated differently. However, I noticed that the bird closest to the side box was browning much more quickly, so about half way through I stopped the rotisserie, switched the chickens on the spit, and continued on. They all three came out great in about four hours. Next time I'll try rotissering three chickens over coals directly under them in the main fire box. I shouldn't need to switch the birds on the spit when I do that. Fifth Stage: Direct grilling, burgers and steaks. 5 stars. Not much to add here. I put about seven pounds of charcoal briquettes in the main fire box tray, raised the tray as close to the cooking grills as I could get it. (The coals were about two inches away.) I let the grills get good and hot, brushed a little oil on them, and grilled a whole mess of burgers and steaks, with hot dogs around the sides. Everything came out great, very fast, too. Even when my wife and I are alone, we often will grill a few dozen burgers and dogs at once and freeze them. We have charcoal grilled burgers and dogs for months after just heating them up in the microwave. Sixth Stage: Cleanup. 5 stars. I don't see how it could be easier. I waited until the grill had cooled then scraped the cooking grills with a wire brush. That took about a minute. The side fire box drawer pulled all the way our for easy dumping of the coals I had used to season the grill. After removing the four main cooking grills, the main charcoal grate lifted right out with the two side handles, and that was just an easy dump, too. On second thought, I think it might be better to scrape the cooking grills with a wire brush while they're still hot. That way you can immediately re-season them with vegetable oil after the wire brush scraping. I'll try that next time. (EDIT: I did try this, and it works well, too.) As far as cleaning up the ashes is concerned, that's very easy, too. Almost all of the ashes in the side fire box will be in the drawer, which slides completely out for dumping. Depending on how heavily you fill the side box with charcoal, there may be some spill-over into the side box itself, outside the drawer. So every few uses you have have to reach in--when it's all cool, of course--and scrape some ash residue out by hand. Pretty much the same applies to ashes in the main fire box, except that there's no drawer. You must remove all four cooking grill sections, then lift out the fire tray and grate. Again, depending on how full you filled it with charcoal, you may have some spill-over ashes that will have to be removed by hand, once they are cool. I found that the easiest way to do this is with a sheet of flexible plastic--one of those thin, flexible plastic cutting "boards" (really more a cutting sheet) works very well, but any thin plastic sheet should work fine, too. Next stages of this review will include durability, and anything else that occurs to me.

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Excellent product...The Real Deal...not cheap workmanship or flimsy. If you want to do real Texas BBQ, this is the one 4 U. And, the side fire box is key. Can then be used as a true smoker, or as a giant grill. Awesome. Can't say enough how well this is built. I looked at lots of different brands and this is one of the best smokers out there. The way they cut the barrel is perfect, right in the middle, which allows maximum room for grilling and/or to stand whole chickens up in the center while they cook. PS...the picture here does not show the side fire box, but it did come with it as described. J.