I got wood. Genesis wood that is.

[Bman]

Peaspurple started a thread where he picked up an older Red Genesis gasser where the original wood slats were missing/beyond their usefullness.  I've been contimplating making reproduction pieces for a while, and this was the motivation I needed to get rolling.

I started with a 1X6 piece of redwood (which is sold at the local lumber yard) and an original (used) Weber handle



Ripped to width, I made 3 blanks longer than they needed to be



Using the stock handle as a jig, I drilled & rough cut the openings before firing up the router table to clean em up



The finished products.  I tried a couple different techniques and now have this down to a science.  The handle next to the original is perfect.



I rounded over the outside edges of the handle and beveled the interior openings (just like the stock handle)



As you can see, I had a handle which has seen better days. 
(Not the stock lid on this gasser, but I used the plastic one for a different task until I made these)



And now, it's just like new.

[Bman]

With the handles made, I went to work on the side table/bottom rack slat replacements.

On the left is an upper side table (measures 10-3/4" long)
On the right is bottom rack (measures 11-7/8" long)
Both use the same size slats, so I made mine just a hair wider than stock.  (1-5/8")



Same photo, only the upper table is flipped over



Used the remainder of the 1X6 and made as many slats as I could



I didn't actually replace the slats, but I'll update this thread when I clean/paint the support bars. 
This gives you an idea what the spacing would look like. Side table first.



Bottom rack



The fruits of today's labor



Close up view of the rounded edges.  (same roundover on the stats & handles)
Weber doesn't round over the end grain and I think this added detail will have a better fit-n-finish on the side table



Since I already had the hunk of redwood on hand, I can't give a cost estimate for members right now.  If you're interested in any of this stuff, shoot me a PM and we'll work something out.  I'll swing by the lumber yard and see what redwood cost and go from there. 

I have a number of older side shelves & bottom wooden racks so I could supply a few sets of wood & hardware if you're missing the entire thing.

Thanks for looking,
Bman

[pbe gummi bear]

Well done!

[unl1mtd]

Nice craftsmanship.

[SixZeroFour]

Outstanding work Bman, as good or better than new!

[Jeff]

Nice work for sure.  Look forward to seeing all of it assembled and on the grill!

[Troy]

WOW.

For the first time ever, I want to buy a gasser!!

Great work Bman!!
If you want to sell them, I'd be happy to help you promote them on the main site.

[G$]

HOW COME THE THANK YOU BUTTONS ARE GONE?!?!!?


This is really really great stuff BMAN.

[Troy]

HOW COME THE THANK YOU BUTTONS ARE GONE?!?!!?


This is really really great stuff BMAN.

THEY WERE NEVER HERE IN THIS FORUM.
I WILL GO ENABLE NOW.

[Troy]

There we go. Now we have thank you buttons here
=D

[AZ_MIKEY]

Don't own a gasser but can see that many of them will look alot better in the future. Good work!

[Idahawk]

  Of course the next question is, are they available ?

[Chuck]

Awesome work there.

[crumbsnatcher]

Beautiful craftsmanship on the handles and slats Bman!  If I come across any red headed gassers, I will definitely PM you for some wood!

[G$]

HOW COME THE THANK YOU BUTTONS ARE GONE?!?!!?


This is really really great stuff BMAN.

THEY WERE NEVER HERE IN THIS FORUM.
I WILL GO ENABLE NOW.

Well, you know, THANK YOU!