Jumbo Joe One Touch Mod

[jksay1974]

I modified a 22.5" one touch cleaning kit to fit into my Jumbo Joe. 

Needed:
One touch kit (Amazon $14.99)
Paper
Pen
Scissors
Sharpie
Aviation snips (I used Wiss, straight yellow handled)
Steel Hammer (I used a ball peen)
Block of wood
Hammer (I used rubber dead blow)
Something hard to hammer against (I used my garage floor)
File or sander (I used dremel with drum sander)
Tongue and Groove pliers (Channellocks)
Drill
Step drill bit

I used the 22.5" one touch because it was cheaper to purchase than the 18", and since the kettle on the Jumbo Joe has a ledge for the charcoal grate I was pretty certain that it would need to be modified as well.

      1. Fold piece of printer paper
      2. Align crease with top side center of wiper #3
      3. Trace both outside edges of wiper arc
      4. Cut out pattern
      5. Place pattern inside grill to determine length (point needs to be inboard of the charcoal grate step)
      6. Indent pattern on fold line with daisy wheel screw
      7. Align pattern to wiper (center indent with pivot point of wiper)
      8. Tape pointed end
      9. Bend paper so inside arc mates with narrow straight edge of wiper
    10. Tape pattern
    11. Repeat for other side
    12. Trace pattern onto wiper with sharpie
    13. Remove pattern (carefully, I used the same pattern for all 3 wippers)
    14. Trim along sharpie line with quality straight aviation snips
    15. Smooth out any bends made during cutting (I used a ball peen hammer and a block of wood)
    16. File or sand sharp edges (I used a dremel with sanding drum, be careful to maintain nice arc)
    17. Bend wiper down a few degrees
    18. Test fit into grill
    19. The wiper will not sit flat against the grill surface at this point, adjustments will be needed.
    20. Flatten out the wiper angle a few degrees as needed (I used a rubber dead blow hammer against my garage floor)
    21. Bend the point of the wiper down to close the gap
    22. Repeat steps 7 - 21  for (2) remaining wipers
    23. Remove daisy wheel
    24. Remove center attach fastener for legs
    25. Rotate legs out of the way
**26. From bottom side, drill out pivot to fit one touch (I used a 7/8" step bit, but only drilled to 13/16")
    27. Deburr hole from inside with step bit
    28. Assemble one touch into grill, but do not rotate handle to lock handle into place
    29. Determine if additional adjustments are needed to get the wipers to seal (I used channel locks to close the angle and
          the dead blow hammer to flatten)
    30. Disassemble and tweak as needed
    31. Repeat 28-30 until happy with fit
    32. Assemble one touch fully
    33. Re-attach center fastener for legs.
    34. Enjoy your Jumbo Joe with one touch...


** Note**:  Make sure you are comfortable with how this looks before you proceed, as the original daisy wheel will not bolt back on easily afterwards.  I planned to use the backer for a hole plug if this failed.

[Walchit]

My mind is now blown!

[jmike314]

That is pretty freakin' cool.


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[56MPG]

Well, it is Mod Month after all. Nice job!



Feel free to re-post this mod here if you like:

http://weberkettleclub.com/forums/index.php?topic=43371.msg431776#msg431776

[HoosierKettle]

Very cool. Did you just have to drill the center hole and install it or was there more to it than that?  I'm surprised I haven't seen this yet.


Sent from my iPhone using Weber Kettle Club mobile app

[jksay1974]

Adding mod steps to to the post.  Thanks for your interest.

[jhagestad]

I love this.