These three pictures 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 Picture 3, 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.

These five pictures show the contents of the first layer--the charcoal bowl layer. Picture 1 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 (Picture 2).

Removing the vinyl cover reveals the water pan resting in a sheet of protective bubble wrap (Picture 3).

With the water pan and bubble wrap removed, the charcoal bowl is now exposed and ready to be removed from the box (Picture 4).

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 (Picture 5).

With the cardboard insert removed, we proceed to the second layer--the lid layer. This layer begins with the charcoal ring wrapped in protective bubble wrap (Picture 1).

The charcoal rings sits on a round disc of cardboard placed inside the lid (Picture 2).

With the cardboard disc removed, the lid is now exposed and ready to be removed from the box (Picture 3).

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 (Picture 4).

After removing the second cardboard insert, we proceed to the third layer--the middle cooking section layer. This layer contains only the middle cooking section sitting on what appears to be the bottom of the box (Picture 1). However, removing the section reveals that the top cooking grate handles are sticking out of a cardboard insert at the bottom of the box (Picture 2).

Removing the third cardboard insert reveals the fourth and final layer--the grates layer. 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.

When you buy a Weber Bullet in a retail store, you can examine the box for damage prior to purchase and you can easily return the unit for a refund or exchange if you find a problem after getting it home.

Unfortunately, people who buy from retailers over the phone or on the Internet don't have it so easy. Most units are shipped by UPS to your home, and sometimes the box is in pretty bad shape by the time it arrives. Sometimes the packing tape that seals the box has failed. If the box is dropped during shipping, the stacked parts can compress into one another, tearing the cardboard inserts between layers. The edges around the top of the box are susceptible to crushing, which can result in damage to the charcoal bowl.

To be fair, this packaging was probably adequate in years past when most WSMs were shipped directly to stores rather than to consumers. I should also point out that Weber Customer Service is always quick to replace any damaged parts at no charge to you. And of course, the shipping companies should take better care of the packages entrusted to them.

However, given the frequency with which retailers are now shipping the WSM directly to consumers, it would be better for everyone involved--Weber, shipping companies, and especially the consumer--if Weber improved the packaging so it offered better protection during shipping.

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

The bright side of WSM packaging is that virtually all of it is recyclable or reusable. The cardboard material and paper bag can be recycled, and the bubble wrap can be saved and reused when boxing up other packages. Even the plastic wrapper around the vinyl cover may be recycled in some communities.

The packaging does not indicate what percentage, if any, of the material is made from pre- or post-consumer recycled materials. The corrugated fiberboard appears to be made from unbleached paper.