So I keep kicking the mini Ranch idea around my head... I would like to have a solid base for the 26er without dropping it into a Performer cart so that brings us to the crazy obsessive place I am now.
I know that one option is to purchase the Ranch legs directly from Weber (I have a Ranch so they would allow it) or replace for approximately $194 shipped at another online parts store. While I know this method works it has some disadvantages.
1.) Cost. I could purchase superior materials that would meet or be below this cost in my opinion.
2.) Seeing how the regular Ranch frame was built I really wasn't impressed and it comes with the bowl brackets that kind of look out of place and ruin a perfectly good storage space under the grill.
3.) The design depends on drilling into the porcelain bowl 8 times AND getting all of them level. It can be done, but that porcelain always seems indestructible until you drop a lid or the bowl tips over (go figure).
So here we are trying to come up with a no weld design because I don't readily have welding tools available and the ones I do have availability to are not set up for Stainless Steel. I would use 1 1/4" square tubing and as much stainless steel hardware as possible. Originally I thought about attaching all the necessary square bar by using corner brace brackets, but I think I may have come up with a better solution visually speaking. The plan would involve drilling a mounting hole on one side of a square tube, inserting a bolt INSIDE the tube, and having the threads be on the outside. Then inserting a tube connecting star nut of some sort inside the other piece of square tube. After that it would take some patience of inserting a wrench inside the tube with the bolt and holding it into place while you turn the whole tube with the star nut. I believe this should work, the only down side is I haven't found any tube connecting nut in stainless steel. It isn't the end of the world because I was planning on keeping the grill inside, but it would have been nice none the less. The other downside is it might get annoying towards the end of assembly.
It may be more secure to keep the cross bars in one piece, but I really dislike this possibility in the event that I wish to add a lower basket or shelf for storage at a later date. I was considering buying a small piece of threaded bar, drilling both sides of the one solid center piece, and then attempting a similar attachment as described above for the two half pieces. I may not be able to get it super tight, but I think I can get it solid enough. I would like to get a basket or shelf, but I will have to see what I can come up with at a later date.
As for securing it to the bowl I am considering buying some flat bar or sheet metal in a 1 1/4" band and wrapping it around the bowl of the grill. Once concern I have is thickness because while I know 1/8" would be solid as a tank I also know that SS can be a pain to bend and shape. My best idea for shaping it would be to make a wood jig and wrap it around while securing with screws until I get the desired shape. Then I could bend the ends out to touch together and use a bolt/nut to tighten around the bowl as needed. The bar would be secured at the lid bail holes, there would be notches for the front handle, and weight would sit on the underside rim of the bowl. The ends of the ring could tuck inside the square tube of one of the legs.
One question I have is there anything I should line around the ring to protect the side and under rim of the bowl that is heat tolerant?
I would secure this ring to the legs not by using bolts, but by cutting the top of the legs in a way where I could slide it into notches of the tube steel. As for the open holes of the legs I am toying around with either cutting them in a way where a square portion could be bent down to secure the ring or simply buying/fabricating some kind of leg caps.
As for the wheels I would look to use a SS axel to secure 8" Weber wheels. While I like the giant wheels on my current ranch I fear that they may be over doing it on a 26er but I could change my mind. I would also look to buy Stainless Steel casters in a similar or smaller size as I have on my ranch build.
At the need of it all I am actually not planning on painting it. I think I might try to polish/sand out any scratches and make it as shiny as I can and leave it. Why paint stainless steel that will chip when it already looks so damn good and is moisture resistant?
Thats the pian so far. I am not planning on starting this project for a minute so I figured putting it here might get a few nutcases like myself to come forward with ideas or words of advice. I might tag a few people eventually to pick their brains.
I ofcouse would documenting it all on here in case someone else wanted to do the same project. After all the finest form of grill flattery is someone else doing the same!