Forget the black smoke, this has been discussed a number of times. The only way you make black smoke is particulate matter that ends up coating everything in the room!
The smoke volume, OTOH, shouldn't be that difficult. When you start up, give the smoke heater about 10 seconds on a fairly high setting before starting the fan. Use this time for various "prep" sounds before the actual engine start. With the actual engine start, kick on the fan and you'll get a nice cloud of smoke to start. After a few seconds taper it off. With the current Legacy boards, this should all be software.