Yoder Smokers YS640 3-Tier Rack Assembly

Perforated stainless steel rack system for Yoder Smokers YS640 pellet grills. Three removable tiers multiply cooking capacity for beef jerky, ribs, chicken pieces, and wings. Heavy duty construction ensures durability across repeated high-volume cooks. Perforated design promotes even smoke and heat circulation on all levels. Open space below bottom rack accommodates foil drip pans. Available at our Wetherill Park showroom.

The YS640 3-Tier Rack Assembly addresses the primary limitation of single-level cooking: wasted vertical space. Pellet grills generate consistent heat and smoke throughout the cooking chamber, but standard single-grate configurations leave the upper chamber unused. This rack system captures that space, transforming your YS640 into a multi-level smoking platform.

The perforated design differentiates this rack from solid shelving. Perforations allow smoke and heat to flow freely between levels, ensuring foods on upper racks receive the same smoke exposure as foods positioned lower in the chamber. This airflow prevents the trapped heat and uneven cooking that occur with solid barriers.

All three racks remove independently. Load all three for maximum capacity jerky runs. Remove the top rack when smoking whole chickens that need vertical clearance. Configure two racks when cooking a combination of ribs and smaller cuts. The modular design adapts to whatever you're cooking rather than forcing you to work around fixed infrastructure.

We stock the YS640 3-Tier Rack Assembly at our Wetherill Park showroom, home to Sydney's largest Yoder Smokers display, where you can examine the construction quality and see how it fits inside the YS640 cooking chamber.

Key Features

Heavy Duty Stainless Steel Construction

The 3-Tier Rack Assembly uses heavy gauge stainless steel throughout. This material choice ensures long-term durability in the high-heat, high-moisture environment inside a pellet smoker. Stainless steel resists corrosion from meat drippings, smoke deposits, and cleaning chemicals that would degrade lighter materials.

The weight and rigidity of heavy gauge stainless prevent warping under load. When fully loaded with ribs or chicken pieces, lighter racks can sag or bend, creating uneven spacing between levels and allowing food to contact upper racks. Yoder's heavy construction maintains structural integrity even when supporting substantial weight across all three tiers.

Stainless steel tolerates repeated temperature cycling without material fatigue. Pellet grills regularly swing between ambient temperature and smoking temperatures of 110 to 135 degrees Celsius, then back down during cooldown. Lesser materials develop stress fractures or lose shape after repeated cycles. Heavy stainless maintains its form indefinitely.

The material also simplifies cleaning. Stainless steel accepts aggressive scrubbing and degreasing without surface damage. Baked-on residue from long cooks wipes away with standard grill cleaners. The non-reactive surface does not absorb flavours or odours that could transfer between different cooking sessions.

Perforated Design for Even Smoke Distribution

The perforations across each rack surface serve a specific purpose: maintaining consistent smoke and heat flow throughout the vertical stack. Solid shelves create barriers that trap heat below and starve upper levels of smoke. Perforations eliminate this problem by allowing convection currents to circulate freely.

In pellet grills, smoke and heat rise from the firepot, circulate around food, then exit through the chimney. Solid obstructions disrupt this flow pattern, creating hot spots below barriers and cool zones above them. Perforated racks maintain the natural airflow path, distributing heat and smoke evenly across all cooking levels.

The perforation size balances airflow against structural support. Holes must be large enough to allow smoke passage but small enough to support food without items falling through. Yoder engineers this balance to handle everything from whole chicken pieces to individual wing sections without food slipping between levels.

Even smoke distribution produces consistent colour across all racks. Foods on the bottom rack often develop deeper smoke rings and darker bark when solid shelves block smoke from reaching upper levels. With perforated racks, items on the top tier receive comparable smoke exposure to items on the bottom, eliminating the need to rotate racks mid-cook.

Fully Removable Rack Configuration

Each of the three racks lifts out independently, providing complete flexibility in chamber configuration. This modularity accommodates different food types and cooking styles without requiring separate accessories for each scenario.

For beef jerky production, load all three racks. Jerky strips lay flat and require minimal vertical clearance, making triple-stacking ideal for processing large batches. The perforations ensure every strip receives adequate smoke exposure regardless of rack position.

When smoking whole chickens or turkeys, remove the top rack to create clearance for upright birds. The remaining two lower racks still double your cooking capacity compared to the standard single-grate setup while providing the height needed for poultry.

Combination cooks benefit from selective rack removal. Place pork shoulder on the main grate, install one or two tiers of the rack assembly above it, then load the tiers with smaller items like chicken thighs or vegetables. The shoulder occupies the main cooking area while the rack system maximises efficiency in the unused upper chamber.

Quick rack removal simplifies mid-cook adjustments. If temperature or smoke levels need modification based on how food is progressing, lift racks out, make changes, then reinstall. The simple drop-in design requires no tools or fasteners, enabling adjustments without interrupting the cook more than necessary.

Grease Management Capability

The open space beneath the bottom rack provides clearance for foil pans that catch rendered fat and drippings during cooks. This design consideration matters for foods that release substantial grease, such as chicken thighs, pork ribs, or fatty brisket points positioned on upper racks.

Without drip pan accommodation, falling grease lands on the main cooking grate or drips directly into the firepot. Excessive grease in the firepot causes flare-ups that create temperature spikes and deposit soot on food. Grease on the main grate creates cleanup problems and potential cross-contamination between different proteins.

Positioning a drip pan below the rack assembly captures falling grease before it reaches critical areas. The pan contains the mess in a disposable container that simply lifts out after the cook. This approach simplifies cleanup significantly compared to scraping carbonised grease from internal smoker components.

The clearance space also accommodates water pans for humidity control. Some cooks benefit from additional moisture in the chamber, particularly when smoking lean proteins prone to drying. A water pan beneath the racks adds humidity without occupying prime cooking space on the main grate.

Specifications

• Material - Stainless steel (heavy gauge)
• Design - Perforated racks
• Number of Racks - 3 (all removable)
• Compatibility - Yoder Smokers YS640 pellet grills
• Installation Type - Drop-in assembly (no tools required)
• Drip Pan Clearance - Yes (open space below bottom rack)
• Finish - Stainless steel (corrosion resistant)

What's Included

• 1 x Yoder Smokers YS640 3-Tier Rack Assembly (3 removable stainless steel perforated racks)

How to Use

Installing the Rack Assembly

Open the YS640 cooking chamber and remove the standard cooking grates. Clear the interior of any accessories or leftover ash from previous cooks. The rack assembly requires a clean chamber for proper seating.

Position the assembled rack unit inside the chamber. The frame sits on the interior ledges designed to support cooking grates. Lower the assembly into position, ensuring it rests level across both sides. The perforated racks should be evenly spaced from top to bottom.

Test rack removal before loading food. Grasp each individual rack and lift straight up. Racks should slide out smoothly without catching on the frame or chamber walls. If a rack binds during removal, adjust the frame position until all racks move freely. This test ensures you can remove racks mid-cook if needed without struggling while food is in progress.

Close the dome and verify clearance. The top rack must not contact the dome lid when closed. If contact occurs, remove the top rack and use only the two lower tiers. Forcing the dome closed against the racks can damage both the rack assembly and the cooker lid.

Loading Racks for Beef Jerky

Beef jerky production benefits most from the 3-tier system. Jerky strips require smoke exposure but minimal vertical space, making them ideal for stacking across multiple levels.

Cut beef into uniform strips approximately 6 to 8 millimetres thick. Thicker strips take longer to dehydrate. Thinner strips can become brittle. Marinate strips according to your recipe, then pat dry with paper towels before loading.

Lay strips directly on the perforated racks in single layers. Leave small gaps between strips to allow airflow. Overlapping strips will not dry properly in the overlapped areas. Fill all three racks using this single-layer approach.

Set the YS640 to 75 to 80 degrees Celsius for jerky production. This low temperature dehydrates meat without cooking it into toughness. Smoke for 4 to 6 hours, checking strips periodically for desired texture. Properly made jerky bends without breaking when removed from the cooker.

Rotate rack positions halfway through the cook if you want absolutely uniform results. While perforations distribute smoke evenly, minor temperature variations can occur between levels. Swapping top and bottom racks ensures identical doneness across all strips.

Smoking Ribs and Chicken Pieces

Ribs and chicken pieces fit well across the 3-tier system, maximising capacity during competition prep or large gatherings. Remove the top rack to create clearance, or use all three racks if cooking cut pieces rather than full racks.

For baby back ribs, cut full racks in half to create sections that fit comfortably on the perforated racks. Apply dry rub and allow it to set while the cooker preheats to 120 degrees Celsius. Position rib sections meat-side up across the available racks.

Chicken pieces work particularly well in this configuration. Legs, thighs, and wings lay flat and require minimal height. Distribute pieces evenly across all three racks, ensuring each piece has adequate space for smoke circulation. Avoid stacking pieces directly on top of each other.

Cook ribs for 5 to 6 hours at 120 degrees Celsius. Chicken pieces require 2.5 to 3.5 hours depending on size. Monitor internal temperatures using a probe thermometer. Ribs are done when they pass the bend test where the meat cracks but doesn't separate when bent. Chicken reaches safe temperature at 74 degrees Celsius.

Position a foil drip pan beneath the rack assembly when cooking chicken or ribs. Both proteins release substantial fat during cooking. The drip pan prevents grease accumulation in the firepot and simplifies post-cook cleanup.

Batch Cooking for Meal Prep

The 3-tier system excels at meal prep scenarios where you need large quantities of the same protein. Chicken breasts, pork chops, or sausages batch efficiently across multiple racks.

Season all proteins identically for consistent flavour across the batch. Place similar-sized pieces together on the same rack to ensure even cooking. Different thicknesses cook at different rates, so grouping by size allows you to remove finished racks while leaving thicker pieces to continue cooking.

Set the YS640 to your target cooking temperature based on the protein. For chicken breasts, use 165 degrees Celsius for moderate-heat cooking that develops some colour. For sausages, use 135 degrees Celsius for gentle smoking that renders fat without bursting casings.

Check the bottom rack first during cooking. Heat naturally concentrates lower in the chamber, so bottom-level foods finish faster than items on upper tiers. Use a probe thermometer to verify doneness rather than relying on visual assessment alone.

Remove finished racks and transfer contents to storage containers. Foods on remaining racks continue cooking without interruption. This approach allows efficient batch processing where you harvest finished items without disturbing foods still in progress.

Care and Maintenance

Remove all three racks from the assembly after each cooking session. Allowing grease and smoke residue to bake onto racks across multiple cooks makes cleaning progressively harder. Fresh residue removes easily with basic cleaning methods.

Wash racks with warm soapy water and a stiff brush. Scrub perforations thoroughly to remove trapped food particles and grease. Pay particular attention to areas where racks contacted food directly, as these zones accumulate the heaviest buildup.

For stubborn deposits, use a mild degreaser formulated for kitchen equipment. Spray the product onto affected areas, allow it to sit for the recommended time, then scrub with a non-abrasive pad. Avoid harsh abrasives or steel wool that could scratch the stainless steel surface.

Rinse racks completely after washing to remove all soap and degreaser residue. Cleaning product residue can create off-flavours during subsequent cooks. Hold racks under running water until no suds remain and the water runs clear.

Dry racks thoroughly before reinstalling or storing. Water spots on stainless steel are cosmetic but can accumulate over time. More importantly, storing damp racks creates conditions for corrosion in joints or seams. Wipe racks with a clean towel after rinsing, then allow them to air dry completely before putting away.

Inspect racks periodically for damage. Check weld points where perforated sheets attach to frame rails. Look for bent sections or areas where metal has cracked under stress. While Yoder construction is robust, heavy use can eventually cause wear. Identifying damage early prevents failure during a cook when racks are fully loaded.

Store racks in a dry location when not in use. If storing racks inside the YS640 between cooks, ensure the cooker is completely dry. Residual moisture in the chamber can promote corrosion on stored accessories. A climate-controlled garage or shed provides ideal storage conditions.

Frequently Asked Questions

Does the 3-Tier Rack Assembly fit other Yoder models?

No. This rack assembly is designed specifically for the YS640. The dimensions and mounting configuration are model-specific. For other Yoder models, check with your dealer about compatible rack systems designed for those units.

Can I use the standard cooking grates with the 3-Tier Rack Assembly installed?

No. The rack assembly replaces the standard cooking grates rather than working alongside them. If you need both single-level and multi-tier capabilities during the same cook, use the main grate for one zone and install the rack assembly in another area of the chamber if space permits. Most cooks will use either the standard grates or the rack assembly, not both simultaneously.

How much additional cooking capacity does the 3-Tier Rack provide?

Capacity increase depends on what you're cooking. For items that lay flat like jerky strips, chicken wings, or ribs cut into sections, the three racks roughly triple your cooking surface compared to a single grate. For items requiring vertical clearance like whole chickens, you may only fit one additional tier above the main cooking level, effectively doubling capacity rather than tripling it.

Will food on the top rack cook differently than food on the bottom rack?

Minor temperature variations exist between rack levels due to heat naturally rising in the chamber. In practice, these differences are small enough that most foods cook evenly across all racks. For competition-level consistency where every piece must be identical, rotate rack positions halfway through the cook. For typical backyard cooking, rotation is unnecessary.

Can I leave the rack assembly installed when not using all three tiers?

Yes. If you only need one or two racks for a particular cook, remove the unused rack(s) and leave the frame in place. This approach is simpler than removing the entire assembly. The frame alone does not significantly obstruct airflow or interfere with cooking on the remaining installed racks.

How do I prevent smaller items like chicken wings from falling through the perforations?

Position wings and other small items carefully to ensure they rest across multiple perforation areas rather than aligning with a single large hole. Properly trimmed wings and drumsticks are large enough to rest stably on the perforated surface without slipping through. If cooking extremely small items, consider using a perforated foil pan on top of the racks rather than placing items directly on the rack surface.

Can I see the YS640 3-Tier Rack Assembly in person before buying?

Yes. They're available to view and purchase at our BBQ showroom in Wetherill Park, where you can also see the full range of Yoder Smokers and accessories.