If you've ever wondered how to cook the perfect smash burger on a Weber kettle or charcoal BBQ, you've come to the right place.
Hi, I'm Rob from CLD Fabrication, and smash burgers have become one of my favourite things to cook. While I've got plenty of flat plate setups at home, nothing beats firing up the charcoal BBQ. Sure, a smash burger is cooked directly on a hot steel plate, so you're not necessarily getting heaps of charcoal flavour into the meat itself—but any excuse to light a charcoal fire is a good excuse in our household.
In this guide, I'll show you exactly how I cook crispy, juicy smash burgers every time using our CLD Fabrication Smash Grill Plate and 316 Stainless Steel Burger Smasher.
Why Cook Smash Burgers Over Charcoal?
Many people assume a gas BBQ is the best option for smash burgers because you're cooking on a flat plate.
I disagree.
A charcoal BBQ provides incredible heat, making it easy to develop the crispy crust that makes smash burgers famous. Plus, cooking outdoors over charcoal is simply part of the experience.
Whether you're cooking for yourself or feeding a backyard full of mates, a charcoal setup gives you consistent results and an excuse to spend more time around the fire.
The Best Charcoal Setup for Smash Burgers
One of the questions we're often asked is:
"What fuel should I use for smash burgers?"
My preferred combination is:
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Heat Beads briquettes
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Lump charcoal
The reason is simple.
The briquettes provide long-lasting, even heat, while the lump charcoal delivers the intense temperatures needed to create an incredible crust.
By combining both fuels, you get:
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High cooking temperatures
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Longer cooking sessions without constantly refuelling
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A plate that stays consistently hot while cooking multiple burgers
If you've got friends coming over, you'll appreciate having steady heat throughout the cook.
The Perfect Smash Burger Plate
For smash burgers, I always reach for our CLD Fabrication Smash Grill Plate.
It features:
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Two-thirds flat smash plate
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One-third grill section
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Heavy-duty 5mm mild steel construction
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Seasons like cast iron for a naturally non-stick cooking surface
The combination gives you the flexibility to smash burgers while grilling bacon, onions or buns at the same time.
Once the plate is fully heated, there's one important rule...
Keep the Plate Clean and Dry
Don't use:
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Oil
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Butter
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Cooking spray
A dry cooking surface is the secret to authentic smash burgers.
The burger needs to stick to the steel. That might sound wrong, but it's exactly what creates the famous crispy crust.
If the meat slides around because the plate is oily, the burger shrinks instead of spreading thin, meaning you lose those delicious crispy edges.
Choosing the Best Beef for Smash Burgers
For the perfect burger, I recommend using a 70/30 beef mince.
That fat content gives you:
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Better flavour
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Juicier burgers
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Excellent texture
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Patties that hold together nicely
The only exception?
Wagyu brisket trimmings.
They contain an enormous amount of fat, so the patties can become quite fragile and fall apart.
Presentation might suffer a little...
But flavour-wise?
Absolutely incredible.
They're easily some of the best burgers you'll ever eat.
When Should You Season Smash Burgers?
This is where opinions differ.
Many people season the meat after placing the burger ball onto the hot plate.
Personally, I prefer mixing the seasoning directly through the mince just before cooking.
Why?
Because the seasoning actually becomes part of the burger instead of ending up scattered across the cooking plate.
The meat should always be the hero, but the right seasoning enhances the natural beef flavour.
Mix it through immediately before cooking to avoid changing the texture of the mince.
If you prefer seasoning after smashing, don't be afraid to season generously. Once you've added cheese, buns and your favourite toppings, those flavours become much more subtle.
The Right Burger Smasher Makes All the Difference
Not all burger smashers are created equal.
Our CLD Fabrication Burger Smasher is built from 316 stainless steel with a Tasmanian Oak hardwood handle and stainless steel hardware.
We chose timber for one simple reason.
Unlike many "cool touch" handles, timber remains comfortable to hold even after spending extended time over a hot BBQ.
Our burger smasher also doubles as a steak weight.
Optional removable weights increase the overall mass, making it perfect for:
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Smash burgers
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Bacon
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Steaks
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Sandwiches
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Toasties
The generous 160mm diameter base gives excellent coverage, helping create perfectly even burgers every time.
How to Smash Burgers Properly
Once your plate is screaming hot and your burger balls are ready:
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Place the mince ball onto the dry cooking surface.
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Press firmly using your burger smasher.
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Move the smasher in a gentle circular motion while applying pressure.
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Create a thin, even burger.
If everything has gone correctly:
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The meat sticks to the plate.
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The burger smasher lifts away cleanly.
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The burger stays exactly where you smashed it.
If the meat sticks to the burger smasher instead, simply place a piece of baking paper between the meat and the smasher before pressing.
It works brilliantly.
Getting That Perfect Crispy Crust
The secret to an authentic smash burger is the Maillard reaction.
As the burger cooks, you'll notice the top beginning to turn brown.
That tells you the underside has developed the caramelised, crispy crust you're chasing.
At this point, grab a sturdy steel or stainless steel burger scraper.
You'll actually need to scrape the burger off the cooking plate—don't worry, that's exactly what should happen.
Flip the burger and cook for another 1–2 minutes.
If you're adding cheese, do it immediately after flipping.
For perfectly melted cheese, place a cloche or burger dome over the burger to trap the heat.
Don't Forget to Toast Your Buns
One of my favourite features of our Smash Grill Plate is the dedicated grill section. While your burgers are cooking on the flat plate, you can use the grill side to toast your burger buns at the same time.
Spread a light layer of butter on the cut side of your buns and place them onto the hot grill bars. In just a minute or two, they'll develop those beautiful charred crosshatch grill marks while becoming perfectly golden and crisp.
Toasting your buns isn't just about presentation, it adds another layer of flavour and texture. The buttery, lightly caramelised surface helps stop the bun from going soggy and gives every bite that little bit of extra crunch.
When you've got juicy burgers, melted cheese and freshly toasted buns with those classic grill marks, you've got all the ingredients for a seriously good smash burger.
Build Your Burger Your Way
A classic smash burger doesn't need much.
Often, all you need is:
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Crispy beef
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Melted cheese
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Soft burger bun
That's it.
But the beauty of burgers is making them your own.
Load yours with:
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Pickles
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Bacon
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Barbecue sauce
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Lettuce
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Tomato
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Onions
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Jalapeños
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Whatever you enjoy most
There isn't a wrong way to build a burger if you're enjoying it.
Cook Better Smash Burgers with CLD Fabrication
At CLD Fabrication, we build products that are designed by people who actually use them.
Our Smash Grill Plate and 316 Stainless Steel Burger Smasher were engineered to deliver consistent results while standing up to years of serious BBQ cooking.
Whether you're cooking one burger or feeding a backyard full of family and mates, the right equipment makes all the difference.
If you're ready to take your smash burgers to the next level, explore our range of Australian-made BBQ accessories and see why more backyard cooks are choosing CLD Fabrication.
Built tough, Aussie made and engineered for serious BBQ.
Frequently Asked Questions
What is the best meat for smash burgers?
A 70/30 beef mince provides excellent fat content, flavour and juiciness while holding together well during cooking.
Should I oil the smash burger plate?
No. A clean, dry cooking surface allows the meat to stick to the steel, creating the signature crispy crust.
What temperature should a smash burger plate be?
Your plate should be extremely hot before cooking. High heat is essential for developing the Maillard reaction and crispy edges.
Can you cook smash burgers on a Weber kettle?
Absolutely. A Weber kettle fitted with a quality smash plate is one of the best ways to cook authentic smash burgers over charcoal.
Why use lump charcoal and briquettes together?
Lump charcoal provides intense heat, while briquettes offer longer-lasting, consistent temperatures. Together they create the ideal cooking environment for smash burgers.
