Before you start: Make sure you have plenty of fuel. A 20-pound bag of charcoal contains approximately 170 briquettes?
Size: Weight is not really an issue as long as the turkey fits in your grill with the lid closed (note that turkeys over 24 pounds may not fit under your grill lid). At least one-inch clearance between the turkey and lid is ideal. So think structure. A broad, flat bird will fit better than one with a high breastbone.
Thawing: A turkey should be completely defrosted in the refrigerator before grilling. Place the frozen turkey in its original wrapping on a tray in the refrigerator. Allow 24 hours of thawing time for every 4 pounds of turkey (I've found this rule of thumb to be off by a least a day). Never thaw poultry at room temperature.
Food safety: To avoid spreading dangerous bacteria to other foods, always wash hands, utensils, and work surfaces with hot soapy water and a 10% bleach wash after handling raw poultry. Experts have determined that cooking a stuffed bird is more likely to result in food poisoning than cooking a bird without stuffing and cooking the stuffing separately. (Use rubber gloves to handle the bird)
Brining your turkey: If you like a little extra flavor and moistness in your turkey, consider brining it. You must do the submerged brining treatment at a temperature of no higher than 42F for safety reasons. Check out the BBQ List FAQ for methods and recipes. (Brine Recipe)
Setting up your charcoal grill for Indirect cooking: A masterfully grilled turkey requires a steady Indirect Medium heat (350F) for hours.
For a 22-1/2 inch grill, light about 50 charcoal briquettes. (See chart below for other grills.) The coals are ready when all of them have a light coating of gray ash, after 25 to 30 minutes.
Arrange the hot coals evenly on either side of the charcoal grate. The coals should be piled as far as possible to the outside of grate.
Place a disposable aluminum foil drip pan between the charcoal fuel holders to catch drippings for gravy, if desired. Pour a little water into the drip pan and replenish as needed during grilling to keep drippings from burning.
Place the cooking grate over the coals (if you are using a hinged cooking grate, make sure you position the flip-up sides directly over the charcoal fuel holders) and place the turkey directly on the cooking grate centered over the aluminum foil drip pan. Place the lid on the grill. Make sure that all vents are open!
At the end of every hour of cooking, add 6 to 8 briquettes to each pile of coals (you'll be happy you're using a hinged cooking grate). Nestle the new coals within the hot ones to help them light quickly. Place the lid on the grill right away and keep grilling! Cook stuffing in a covered foil pan beside the turkey on the grill, by the Indirect Method, during the last 45 to 60 minutes of grilling time, to an internal temperature of 165F.
How Much Charcoal?
| Diameter of Grill in Inches | Briquettes for the First Hour | Briquettes for Each Additional Hour |
| 14-1/2 | 15 per side | 6 per side |
| 18-1/2 | 20 per side | 7 per side |
| 22-1/2 | 25 per side | 8 per side |
| 26-3/4 | 30 per side | 9 per side |
| 37-1/2 | 75 per side | 22 per side |
Doneness: Turkey is fully cooked when a meat thermometer registers 175F in the thigh or 165F in the breast (about 11 to 13 minutes per pound). Remove the turkey from the grill and allow it to rest for 20 to 30 minutes before carving. See the chart below for approximate cooking times for your size turkey.
(Please note: Turkey is thoroughly cooked when a meat thermometer registers 180F in the thickest part of the thigh or 170F when inserted in the breast.) Allow more time for cold/windy days or high altitudes.
| Cooking times for unstuffed turkeys |
| 10-11 lbs. = 1-3/4 to 2-1/2 hrs. |
| 12-14 lbs. = 2-1/4 to 3 hrs. |
| 15-17 lbs. = 2-3/4 to 3-3/4 hrs. |
| 18-22 lbs. = 3-1/2 to 4 hrs. |
| 23-24 lbs. = 4 to 4-1/2 hrs. |
To make basic turkey gravy: Remove all but 1/4 cup of the fat from the drippings in the roasting pan. Gradually whisk 1/2 cup flour OR 1/4 cup cornstarch into the fat and drippings. Whisk over low heat until smooth, and cook for about five minutes, stirring constantly. Slowly whisk in 4 cups of liquid (broth, cooking water from the boiled giblets, or milk). Stirring constantly, raise heat to medium high and bring to a boil, then reduce heat and simmer until thickened, about 5 minutes, loosening the bits of cooked turkey from the bottom of the pan. Season with salt and pepper to taste.
