DIY Old style One-Touch Gold Ash catcher bar

[pbe gummi bear]

Hi, I decided to make a a template for a replacement ash catcher bar from the older style One-Touch Gold ash catchers. Later on, I hope to make one that is compatible with the newer H-style assemblies. Here's a preview for now!

[javahog2002]

Cool.  That looks familiar.    Too bad it is not easy to locate a ring to fit that bar.

[Troy]

Hi, I decided to make a a template for a replacement ash catcher bar from the older style One-Touch Gold ash catchers. Later on, I hope to make one that is compatible with the newer H-style assemblies. Here's a preview for now!

You sir are a hero and a legend.
Good luck on your quest.

[mike.stavlund]

I just helped a customer for your first production run, pbe.  His ash catcher bar works, but it is looking pretty weak and flimsy.  Sorry and saggy.

Godspeed in your quest. 

[Heyjude]

If Weber is discontinuing the old style OT ash assembly, we need a way to adapt these bars to the newer "H" style assemblies..  So Lawrence, is thsi something we can have made or just the drawing? It would be awesome to order up some of these..AJ 

[pbe gummi bear]

AJ, yeah that's the next project. Ill test this one out this weekend. I need to get my hands on the H style in due time.

[pbe gummi bear]

Can someone post a pic of the bottom of the "H" assembly?

[G]

Go pbe...stainless steel would be ideal and if they fit the H style sweeper, even better.  I remeber a post a few years back about someone crafting these to original specs at a metal fab shop.  I think they had several made that sold out quickly.   

[Bman]

Can someone post a pic of the bottom of the "H" assembly?

This is as close as I can come. 
.

[G]

hopefully this helps too...

[glrasmussen]

Hi, I decided to make a a template for a replacement ash catcher bar from the older style One-Touch Gold ash catchers. Later on, I hope to make one that is compatible with the newer H-style assemblies. Here's a preview for now!

You are the man if you can make this happen. We need a micrometer for the thickness of the "H" clip. The bar will have to be the same thickness. I did do an install, so tight, as the bar is thicker than the "H" clip and it does not lock in.

[pbe gummi bear]

Yeah we can make this happen. I have the mic and digital calipers thanks for the pics! It gets the gears turning.

[pbe gummi bear]

So I went to the hardware store today (OSH) and they only had the screw type in stock. They still had about 4 of them. I did get a chance to look at the new assembly on the new performer. It's more complex than I initially assumed but I have a few ideas I am gonna mock up.

[pbe gummi bear]

Hi, Sorry for the lack of updates. My workstation was on the fritz. Here are the dimensions and sheet metal pattern of the old style ash catcher bar.  It is a little simplified because the original weber one has fillets and curved cuts. These dimensions should get you very close but I have not had the time to try it myself. I printed out the pattern at proper scale though and laid it over the existing bar and it seems to check out. If there are any machinists, draftsmen, engineers or architects in the audience I apologize in advance for the dimensioning. Not my fault, I promise. 

Ash Catcher bar dimensions


Ash Catcher bar sheet metal pattern


I'll have a pdf of the sheet metal pattern up soon. I need to fix it.

[pbe gummi bear]

Testing out the sheet metal pattern. Looks good imo.