I was inspired by a number of threads. The first one is from another forum (The Smoke Ring).
Hogsy's post in the 2nd thread regarding the chimney starter.
The third and fourth deal with charcoal baskets.
http://thesmokering.com/forum/viewtopic.php?t=17750
http://weberkettleclub.com/forums/weber-kettles-accessories/recommend-a-floor-mat-or-pad-please-i-damaged-3-or-4-deck-composite-boards/
http://weberkettleclub.com/forums/food-pr0n/wife-has-been-complaining/
http://weberkettleclub.com/forums/food-pr0n/pizza-and-california-tri-tip/new/?topicseen#new
I put my thinking cap on, and went to it planning it out. I fabricated some of it out of cardboard for use as a template.
Making a piece for the Weber chimney starter was a challenge, too. As it has that cone-shape of wires in it.
I am not an experienced welder. I took a course last year at a local college, so I learned some there.
But, I haven't done much since last summer. Thought, I got to give it a try. I have a POS flux-core wire welder. It does okay. ???
The main reason that I did this, is because I want to start using lump more in the kettle.
So many small pieces. I usually only use lump in my 2 UDS's.
I'm not sure of the longevity of these pieces. Time will tell.
The first pic is of a Smokey Joe. The rest are for the 22.5" kettle.
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-21.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-21.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-8.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-8.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-9.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-9.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-1.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-1.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-2.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-2.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-3.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-3.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-4.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-4.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-7.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-7.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-5.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-5.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-6.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-6.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-10.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-10.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-11.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-11.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-16.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-16.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-17.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-17.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-18.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-18.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-19.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-19.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-20.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-20.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-12.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-12.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-13.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-13.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-14.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-14.jpeg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/messagepart-15.jpeg) (http://s1142.photobucket.com/user/MacEggs/media/messagepart-15.jpeg.html)
THAT's thinking with your dip-stick, Jimmy!
(reference to bad, older radio commercial)
If I could give you more than one "Thank You" I would. Nice work.
Excellent work! I love the fact that you thought to modified the chimney starter as well.
Pretty dang neat & orderly there,Mark..... 8)
Got a lot of different items taken care of with a few short strokes....... 8)
If you happen to have pics of the baskets out of the cookers, that may be instructive to I & others......
i thought of doing a "ring" one kinda like that, but with two uprights, to then keep the charcoal off the wall of the kettle ( like we were talking about in the porcelain damage thread.....)
That is awesome work, nicely done
Nice work. I may try a couple of the myself.
Thanks
Those are very clean Mac! Looks awesome!
"my kettle is more powerful it will do almost anything."
Great work, Mark! Thanks for sharing the details.
Very nice work Mac!
Badass! I love the chimney mod! !
Sent from my Galaxy Nexus using Tapatalk 2
Quote from: 1buckie on June 12, 2013, 01:35:09 PM
Pretty dang neat & orderly there,Mark..... 8)
Understatement! :)
You've culminated in one thread all my wishes for my OTG as I too have a predilection for lump and am remiss to find so much go to waste in the ash pan.
What sort of mesh material is that you worked with?
VERY VERY IMPRESSIVE!!!
I love the the versatility and improvements that you can do with a kettle all it takes is an idea a bit of know how and some experimentation
Can you explain the set up with the third photo.....is that to setup a snake method type cook?
Thanks, that will give me something to work with and modify for my specific needs. I don't have access to welding equipment, but I would imagine using wire or nuts/bolts/washers would also work. Maybe a little crude looking, however, I don't expect my "butts" to be too concerned.
BTW, if I do use wire, what is the best material to use?
Any wire that's not galvanized should be sweet
Quote from: colin.p on June 13, 2013, 03:45:02 AM
Thanks, that will give me something to work with and modify for my specific needs. I don't have access to welding equipment, but I would imagine using wire or nuts/bolts/washers would also work. Maybe a little crude looking, however, I don't expect my "butts" to be too concerned.
BTW, if I do use wire, what is the best material to use?
I wonder how much welding you could get done in exchange for some BBQ? For a number of these projects it's just a touch here and there. Lucky for me my son has a small MIG welder but unfortunately we only head that way several times/year.
As far as wire, I use some I got at the home repair store that is intended to be used to wire concrete reinforcing bar together. It's soft steel and easy to work with and won't poison me. I find both it and the expanded metal can rust away in a year or two, but are easily enough replaced.
Also I recall seeing that someone folded over the expanded metal to make a joint. I don't recall if that was here or at BBQ-Brethren.
Thanks for the pattern for the chimney. I've been meaning to do that!
Quote from: HankB on June 13, 2013, 03:56:26 AM
Quote from: colin.p on June 13, 2013, 03:45:02 AM
Thanks, that will give me something to work with and modify for my specific needs. I don't have access to welding equipment, but I would imagine using wire or nuts/bolts/washers would also work. Maybe a little crude looking, however, I don't expect my "butts" to be too concerned.
BTW, if I do use wire, what is the best material to use?
I wonder how much welding you could get done in exchange for some BBQ? For a number of these projects it's just a touch here and there. Lucky for me my son has a small MIG welder but unfortunately we only head that way several times/year.
As far as wire, I use some I got at the home repair store that is intended to be used to wire concrete reinforcing bar together. It's soft steel and easy to work with and won't poison me. I find both it and the expanded metal can rust away in a year or two, but are easily enough replaced.
Also I recall seeing that someone folded over the expanded metal to make a joint. I don't recall if that was here or at BBQ-Brethren.
Thanks for the pattern for the chimney. I've been meaning to do that!
That was here. Bman did that when he needed a splice for his charcoal ring.
Outstanding fabrications!
Nice job! I love the baskets especially!
Quote from: sunsanvil on June 13, 2013, 03:29:50 AM
Quote from: 1buckie on June 12, 2013, 01:35:09 PM
Pretty dang neat & orderly there,Mark..... 8)
Understatement! :)
You've culminated in one thread all my wishes for my OTG as I too have a predilection for lump and am remiss to find so much go to waste in the ash pan.
What sort of mesh material is that you worked with?
It's FLAT expanded metal.....you want to look for / ask for flat, it comes also where the manufacture lets it buckle up at the lip of each diamond shape.....harder to work with, harder to clean, more likely to cut yourself handling.....it has it's uses, just not this stuff we're doing........
The bigger pieces ( upright for the full ring) look like #9 ~3/4", the standard for large pit grates, the other stuff is probably 1/2" which I have a bunch of.....thought that might be better for tight, small areas......
Look for a metal selling place around where you live, the recyclers may or may not have anything you can sift thru to find this stuff,the place I go has all kinds of end cuts for cheap / by the pound.......
And +2 or 3 for UN-galvanized steel wire....it may rust at some point, but a fairly easy fix......
The other real good reason to keep lump bits contained is that they're real hard on the One Touch sweeps.......anybody notice that>?
Quote from: 1buckie on June 13, 2013, 06:07:02 AMThe other real good reason to keep lump bits contained is that they're real hard on the One Touch sweeps.......anybody notice that>?
Not (yet). Seems to me the stock grate spacing is virtually identical to the vent aperture at the bottom of the bowl. So if it falls down that far a sweep of the OT and they are in the pan. The filp side of course is that there is precious little actual ash anyway...
Slightly off topic I've got a couple brands of lump, one is annoyingly small, the other massive, almost too big if there could be such a thing. I'm going to experiment this weekend with laying some large pieces on the grate and topping them with lit small ones to see if A) I end up with less waste down though, and B) if the burn will propagate at the right rate for a longer than 30 minute cook. :)
"B) if the burn will propagate at the right rate for a longer than 30 minute cook."
Just pinch down your vents a little at the start & come UP TO your temp............
Just reading this now.
A little tired from doing all that work yesterday .... plus I stayed up and watched the triple OT BlackHawks victory. :D
Thanks for looking. Thank you all for the kind words, too! I appreciate it. I truly hope it helps. :)
I'm fortunate enough to have a buddy (he's also a BBQ buddy), that operates a sheet metal shop. He's got lots of EM.
We are always doing trades, and helping each other out. He gave me some scrap pieces for this project.
The EM that I used is not thick. The welder can melt it very easy if inexperienced (that's me). ??? I had to be very patient.
I like to weld, and do long passes. The work on these baskets was all tack welding. Very tedious, to say the least. I persevered. ;)
If these things fall apart, then I will try to get thicker stuff. I will then have some experience to hopefully make them better. :) :D
In the 2nd and 3rd pics (beginning of thread), I did not weld those pieces together, as, I made two rings with different widths.
And, yes, Hogsy, I made those pieces for the snake / fuse method. :) I'm hoping to try them out this weekend for Father's Day.
I need more EM, as, I am considering making some sort of ring (2 pieces) to act as a buffer around the inner bowl as discussed in the following thread.
http://weberkettleclub.com/forums/weber-kettles-accessories/is-porcelain-enamel-damage-common/
Here are a few more pics, as per requested.
(http://i1142.photobucket.com/albums/n615/MacEggs/IMG_1785.jpg) (http://s1142.photobucket.com/user/MacEggs/media/IMG_1785.jpg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/IMG_1786.jpg) (http://s1142.photobucket.com/user/MacEggs/media/IMG_1786.jpg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/IMG_1787.jpg) (http://s1142.photobucket.com/user/MacEggs/media/IMG_1787.jpg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/IMG_1788.jpg) (http://s1142.photobucket.com/user/MacEggs/media/IMG_1788.jpg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/bb953986-654c-47e4-abf1-c5b25c1041d8.jpg) (http://s1142.photobucket.com/user/MacEggs/media/bb953986-654c-47e4-abf1-c5b25c1041d8.jpg.html)
(http://i1142.photobucket.com/albums/n615/MacEggs/IMG_1790.jpg) (http://s1142.photobucket.com/user/MacEggs/media/IMG_1790.jpg.html)
Just one last question: How much for a pair of baskets plus the chimney insert? ;)
Quote from: sunsanvil on June 13, 2013, 08:14:51 AM
Just one last question: How much for a pair of baskets plus the chimney insert? ;)
Hopefully I don't sound like a d!ck, but, make some up yourself. :D ;) ;) Did that sound rude? I hope not. :-\ :-\
I recommend making a template using cardboard. Thin stuff, like the stuff used for cereal boxes for the curved part.
Then tape the 3 pieces together to get an idea of what you need to do.
The measurements are there. They're not perfect, but, that's what practice is all about. 8)
Sounds l;ike Mac is tried of tack welding for awhile....... 8)
The lighter weight stuff can be cut with hand-held metal shears or a hacksaw & a cutting torch is not then needed, it's some hassle, but not the end of the world....... ;D
Wire twists (I would think from the inside, so they don't catch on other stuff when in use) will finish things off.....
Quote from: 1buckie on June 13, 2013, 08:52:08 AM
Sounds l;ike Mac is tried of tack welding for awhile....... 8)
The lighter weight stuff can be cut with hand-held metal shears or a hacksaw & a cutting torch is not then needed, it's some hassle, but not the end of the world....... ;D
Wire twists (I would think from the inside, so they don't catch on other stuff when in use) will finish things off.....
You got that right, Ken. :( >:( ;) Gonna get out and visit Roxy at the deli for a mile high sammich! 8)
I used a cutting wheel on my grinder to do the cutting and smoothing. Works quick. :)
" Gonna get out and visit Roxy at the deli for a mile high sammich!"
Pics....or it didn't happen.....feel at home now ?
Very nice
Quote from: 1buckie on June 13, 2013, 09:03:55 AM
" Gonna get out and visit Roxy at the deli for a mile high sammich!"
Pics....or it didn't happen.....feel at home now ?
Had a nice visit. Ate a huge sammich, home-cut fries, then shot the breeze for awhile, too. No pics .... yeah, it's good to be home. ??? ;D :P
Now this is what I like about this forum. Someone comes out with a kick-$%# idea and posts it on here, well-documented with copious pictures. Now if I don't slice off an important appendage when I make my own baskets....
Quote from: colin.p on June 13, 2013, 01:15:51 PM
Now this is what I like about this forum. Someone comes out with a kick-$%# idea and posts it on here, well-documented with copious pictures. Now if I don't slice off an important appendage when I make my own baskets....
Thanks for the compliment! I cannot stress this enough .... You gotta wear gloves with EM, because it will cut / slice you if you're not careful. ??? :-[
Quote from: colin.p on June 13, 2013, 01:15:51 PM
Now this is what I like about this forum. Someone comes out with a kick-$%# idea and posts it on here, well-documented with copious pictures. Now if I don't slice off an important appendage when I make my own baskets....
It's like I was tellin' Golly in this thread.......
http://weberkettleclub.com/forums/weber-kettles-accessories/rare-weber-for-wkc-meet-showoff/30/
Quote from: 1buckie on June 11, 2013, 08:04:32 PM
Quote from: Golly on June 11, 2013, 07:29:59 PM
Fark me
I'm excited
Sounds like some real weber p0rn
I've got a chubby
Quote
Take care not to singe yer nubbin on the side of the kettle.............. 8)
....mind your nubbin...... 8)
Good lord, I just had a horrifying vision of an old fat guy grilling with nothing on but an apron and a smile. However, I can assure you, even though I'm fat and old, I only grill outside fully clothed, especially with all the bleeding mosquitoes we have.
Excellent work, this gets a Bump...
(http://assets.head-fi.org/5/5d/5dcbda69_122312d1238514875-sg-glass-auction-topia-april-fundraiser-bump.gif)
First of all great work - I now know what I will be doing all weekend. I'm sure at some point the Boss will make me attend some 2yr old's birthday party,stating that we are required to go because we know their friend's babysitter's boyfriend :o - but other than that this will be a top priority.
Never call a post "Pic Heavy" when the pictures can placed in two categories simultaneously - being both 'grill p0rn' and featured in 'Bob Vila's - How to Center'. I will be using this as a guide when I assemble my baskets for my 26. I have wanted to do all of this for awhile. Much like you I was all over the internet looking at similar projects but I had so many unanswered questions that kept me from doing it - but not any more - seriously thank you for taking the time to post.
Having fun playing with fire again I see, although im 2 years late on comments.
In the 2nd & 3rd pic of the fire grate with the ring. Are you using that one to burn lump similar to how I did it in your first link (rimfire)? Reason I ask is because I like to use the exp. on the kettle side to provide a bit more air which I think allows the lump to burn more completely without much if any small pieces left over after the burn passes by. Its not necessary just the impression I gave myself after multiple test fires, before and after the fattys.
The baskets...I hate the schitty little tin baskets Weber passes off as a constellation prize for buying their grill, the older wire ones work better but alas two fires in one hole intrinsically creates instability, arguably. You have the right idea making them with exp. and making them deeper but I think they'll work better with a different shape. In my test fires with the baskets I'v made I got the best results (duration, complete burn, and potential) with a bean shaped pair. In my mind two baskets are an obsolete lo-&-slo method after the rimfire or snake method.
If the purpose for the baskets are to focus heat for high heat grilling or for cooking small a single small round basket, without a partition, will work better than the hokus pokus aluminized tin baskets. As much R&D as weber does you'd think they would have figured that out....
Also Im not saying two baskets WILL NOT work what I am saying is theres a better/no hassle way.
Maybe they work fine with briquettes, I wouldn't know, I dont use briquettes. Mine were disassembled and used on another experiment years ago.
The screen on the rapidfire is served well by adding the exp. metal. That was a damn fine idea! Im sure you've picked up on the tip to invert it? Itll take less fuel to light it and hold more fuel if you need it too. Iv thought about using some SS window type screen, I scored from BBQMAN for my dehydrator, to cover the bottom so it dont cough so many sparks into the air when you dump it. A California spark arrestor so to speak.
Wow, this thread is old ....
@Hell Fire Grill :
In the 2nd & 3rd pic of the fire grate with the ring. Are you using that one to burn lump similar to how I did it in your first link (rimfire)?:
My main reason for it was to try to create as much space in the center to allow for a larger cut of meat.
I prefer to use briquets with a snake / fuse for a more consistent burn. I have used the ring with great success. Here are a couple threads:
http://weberkettleclub.com/forums/grilling-bbqing/fuse-snake-lasted-11-plus-hours/
http://weberkettleclub.com/forums/grilling-bbqing/brisket-made-easy-with-a-weber-kettle/
The baskets...I hate the schitty little tin baskets Weber passes off as a constellation prize for buying their grill:
Ya, good point. I have one that I got from a rescue. Not enough air flow, I believe.
I hope to fabricate a basket using EM modelled after these, but a little taller.
I do like the fact that they will fit the 18" kettle, as well.
I have also fabricated a round basket that is the same diameter as a charcoal grate for a 18" kettle. Seen HERE (http://weberkettleclub.com/forums/grilling-bbqing/charcoal-layout-for-grilling/msg170835/#msg170835).
In my mind two baskets are an obsolete lo-&-slo method after the rimfire or snake method.:
I like using the two baskets opposite each other when doing a turkey, or something along those lines with a drip pan in the middle.
I will also center the baskets for grilling steak with baked potatoes on the perimeter (indirect). One basket is all I need for ribs.
The screen on the rapidfire is served well by adding the exp. metal. That was a damn fine idea! Im sure you've picked up on the tip to invert it?:
Thank you! And, yeah I do that all the time. Works great.