Hello, all of these cool WSM in a performer cart mods have inspired me to finally start building the Weber I've been dreaming about for years: a 22.5" WSM in a SS Performer cart. My goal for this build is to keep everything as OEM as possible to make it look like it came from the factory or better. This build will have:
Gas Assist
One touch AND WSM daisy wheels.
OTG ash Catcher
Standardish WSM height. I'm a short asian so popping the WSM midsection and lid on a normal height performer is a no-go.
SS performer cart, flip up table, and charcoal bin.
Roti-ring (CB?) and/or Stacker
Stoker wi-fi.
I hope you enjoy this build log. Special shout out to
@Winz,
@SixZeroFour,
@TexasOnion @Jeff for their inspiring hybrid creations!
Can't wait to see and hear about this!
Oh boy, this is going to be a good one....
Looking forward to the build. Gas assist on a WSM - that is certainly a first.
Winz
Day 1- Making the Frame
This Green SS Performer is my Donor Cart. It's in great shape but Green is not my color
(http://pics.weberkettleclub.com/images/2015/06/13/image.md.jpg) (http://pics.weberkettleclub.com/image/1j)
First order of business is to strip down the cart. This only takes a few min.
(http://pics.weberkettleclub.com/images/2015/06/13/image9fd78.md.jpg) (http://pics.weberkettleclub.com/image/1E)
Next I cut the welded support bars off the kettle side of the table. I need to spread the bolted horizontal crossbars apart in order to fit the kettle and OTG ash catcher down low. I left the welded support bar opposing the kettle because it's not getting in the way of anything
Cut using a jigsaw. Sorry for the misrotated pic. I actually didn't cut like this, I just wanted to show that a jigsaw fit here. I felt that an angle grinder was overkill and a dremel can't reach in there that well
(http://pics.weberkettleclub.com/images/2015/06/13/image8e44a.md.jpg) (http://pics.weberkettleclub.com/image/1N)
Sparks while smoothing out the leftover welds.
(http://pics.weberkettleclub.com/images/2015/06/13/image5ab1f.md.jpg) (http://pics.weberkettleclub.com/image/1V)
Test fitting the kettle. I wanted the kettle as low as possible while still allowing for removal and installation of the ashpot. There's ~1" clearance below the ashpot to move it in and out. The performer bowl is now structural as it's the only thing that provides torsional rigidity on that side of the frame. Recall that we cut the crossbar out from that side.
(http://pics.weberkettleclub.com/images/2015/06/13/image076b1.md.jpg) (http://pics.weberkettleclub.com/image/17)
It fits! crossbars are 18.5" ground-to-top. They are attached to the legs with the OEM star nuts and 1/4-20 bolt. I then drilled them to mount the kettle with the standard tabs. I also offset the kettle by roughly one inch closer to the end of the frame. This gives the midsection proper clearance to the radius-cut ss panel. The standard performer kettle hangs a little bit over this panel and I didn't want the panel banging into the midsection's porcelain when I wheel this thing around. Finally, the wheel axle hits the ashpot by about 1". I'll cut it down later and figure out another attachment method for the wheels.
(http://pics.weberkettleclub.com/images/2015/06/13/image9e794.md.jpg) (http://pics.weberkettleclub.com/image/19)
The one thing that i didn't anticipate is the the midsection barely fitting through the legs. There is a mild interference of ~1/2" at the bottom flared edge. It's pops right through though. Because of this I'll probably be less inclined to take the midsection on and off too frequently and hurt my porcelain. Good thing I'll have the OT to clean out my bowl. ;D
Other things to do to the frame:
Cut the axle to clear the ashpot.
Think about moving the propane tank and ignition switch.
Touchup.
Amazing.
Love it. Looking forward to the next instalment
Gummi - great progress. I really like how low it sits in the frame. Mounting the base to the bottom rail is genius - makes is look very OEM.
A couple of ideas:
1) regarding the axle - I ditched the axle when building Bisbee so that I could mount some custom wheels. I simply drilled out the holes in the frame and replace the axel with bolts.
(https://dl.dropbox.com/s/0z4p354pto5hwss/Axel%20bolt.jpg?dl=0)
(https://dl.dropbox.com/s/7212yyz4uv455do/Axel%20Spoke.jpg?dl=0)
You can probably find a better "hubcap" option, but you get the idea. Would love to see some custom wheels on your build. I think you did this mod before with some pneumatic tires from what I remember.
2) I like that you are thinking about relocating the tank. It is my least favorite feature of the SS performers as it is big, white, and very visible. It is pretty easy to replicate the cuts that hold the top of the tank bracket, and relocate the bracket from the front of the cart to the back. This won't entirely hide the tank, but it really helps.
You already have a ton of work done in a very short time. Looking forward to the next installment.
Winz
Very nice build! I like it because it looks factory built.
Nice build , I'm tall so I'd go the other way . I can't score a ss performer as the closest ones been 200 mi away ( one way) I'm going larger wheels & 3" casters for my mod on current performer as it travels over several acres. Yours looks sweet
Cheers
Quote from: Winz on June 14, 2015, 05:49:38 AM
Gummi - great progress. I really like how low it sits in the frame. Mounting the base to the bottom rail is genius - makes is look very OEM.
A couple of ideas:
1) regarding the axle - I ditched the axle when building Bisbee so that I could mount some custom wheels. I simply drilled out the holes in the frame and replace the axel with bolts.
(https://dl.dropbox.com/s/0z4p354pto5hwss/Axel%20bolt.jpg?dl=0)
(https://dl.dropbox.com/s/7212yyz4uv455do/Axel%20Spoke.jpg?dl=0)
You can probably find a better "hubcap" option, but you get the idea. Would love to see some custom wheels on your build. I think you did this mod before with some pneumatic tires from what I remember.
2) I like that you are thinking about relocating the tank. It is my least favorite feature of the SS performers as it is big, white, and very visible. It is pretty easy to replicate the cuts that hold the top of the tank bracket, and relocate the bracket from the front of the cart to the back. This won't entirely hide the tank, but it really helps.
You already have a ton of work done in a very short time. Looking forward to the next installment.
Winz
Thanks for the tip, Winz. (1) is exactly what I planned to do!
There's also a chance that I'll replace the GA with the new style.
Looks great so far, I love the idea of keeping it lower in the cart. Craftsmanship looks top of the line too.
That looks awesome. I'd love to see some close up pics and measurements of the clearance between the legs and flared part at the bottom of the WSM midsection. I have a WSM and an extra SS cart and have wanted to do something similar.
Quote from: terrymo on June 14, 2015, 07:23:00 PM
That looks awesome. I'd love to see some close up pics and measurements of the clearance between the legs and flared part at the bottom of the WSM midsection. I have a WSM and an extra SS cart and have wanted to do something similar.
They are coming. I spent some time outside today gathering clearances and taking pics. 8)
I like it very cool! I wonder if you could widen the other end would it alleviate the resistance at the bottom? On the tank showing maybe you could make a panel of SS from the bottom rail up to the OEM panel?
GO GUMS!!
Clearances.
The midsection clearance issue isn't as bad as I originally thought. The midsection rolled lip at the bottom is the widest part which measures ~22.5" (estimated from the bowl lip as they are pretty darn close). The gap between the legs is closer to 22".
(http://pics.weberkettleclub.com/images/2015/06/15/image57f0f.md.jpg)
(http://pics.weberkettleclub.com/images/2015/06/15/image8d417.md.jpg)
Theres about .75" of interference between the ashpot and axle.
(http://pics.weberkettleclub.com/images/2015/06/15/imagea3697.md.jpg)
The leg bolts stick out a bit and hit the midsection. I may grind them down or get buttonhead screws instead. The bend in the front panel also hits it a bit.
(http://pics.weberkettleclub.com/images/2015/06/15/imagedd4e4.md.jpg)
Kettle pushed all the way towards the frame legs
(http://pics.weberkettleclub.com/images/2015/06/15/image.md.jpg)
.5" of clearance around the SS panel and midsection
(http://pics.weberkettleclub.com/images/2015/06/15/imagee4f1c.md.jpg)(http://pics.weberkettleclub.com/images/2015/06/15/imagee91bf.md.jpg)
Looking great so far Gummi! Cant wait to see the finished product!
Thanks for the pics and measurements. I'm brainstorming a similar project so I appreciate the step by step you are showing.
You could take a piece of 1" diameter tube and split it lengthwise so you you have two halves with a "c" profile. Use the "c" shaped end to scribe a line on the legs at the height the flared portion of the bottom of the midsection would need to pass through the legs at a height that the bottom of the midsection would clear the bowl prior to setting the midsection down into the bowl. Remove the material from the leg, cut the "c" channel length to match the width of the leg, and weld these pieces of "c" channel onto the legs. This would give you the clearance to remove and replace the midsection using the handles you installed without any rubbing. Maybe epoxy some black high temp silicone sheet into the "c" channel to keep from damaging the porcelain of the midsection. I don't think you would lose any structural integrity of the legs, especially since the weight of the WSM is on the cross section pieces rather than the factory location. Maybe not necessary but it's easy to brainstorm when you're spending someone else's time and money. 8) Hopefully that made sense.
Just wondering, are you planning to use any counter balance on the front? Wouldn't want your cart to be doing wheelies when that 22" is loaded with meat and charcoal. Also, Awesome job. There are better "Out of the Box Thinkers" on this website then at Weber.
Nice......I have been contemplating a similar project for months, but have been too busy. My big decision was if I wanted to use the WSM bottom section or the kettle bottom. I was concerned about the gas assist lighting more coals than I wanted. I guess you could light a small amount of coals with the gas assist and then dump rest of the bag on top of the lit. I usually do the opposite, but there are many ways to skin a cat. Thanks for the post. Looks like it is moving along nicely and I'm interested in how it turns out
Quote from: OoPEZoO on June 16, 2015, 07:47:39 AM
Nice......I have been contemplating a similar project for months, but have been too busy. My big decision was if I wanted to use the WSM bottom section or the kettle bottom. I was concerned about the gas assist lighting more coals than I wanted. I guess you could light a small amount of coals with the gas assist and then dump rest of the bag on top of the lit. I usually do the opposite, but there are many ways to skin a cat. Thanks for the post. Looks like it is moving along nicely and I'm interested in how it turns out
I think it's a great mod so I hope you get around to building your own version. I wanted to have the OT for cleaning so using the performer bowl was an easy choice. I'm adding daisy wheels to have the best of both worlds.
My thoughts were to mount the WSM onto a hinged shelf on the bottom of the performer frame. That way when I wanted to empty the ash I could just swing the WSM base/shelf up vertical and sweep it out. No idea if it's feasible as I haven't started test fitting anything yet, but that's my thoughts now. I'll get to it at some point in the next few months. Too much going on with life and work right now
Quote from: OoPEZoO on June 16, 2015, 12:19:41 PM
My thoughts were to mount the WSM onto a hinged shelf on the bottom of the performer frame. That way when I wanted to empty the ash I could just swing the WSM base/shelf up vertical and sweep it out. No idea if it's feasible as I haven't started test fitting anything yet, but that's my thoughts now. I'll get to it at some point in the next few months. Too much going on with life and work right now
I've thought about this too and it would be a sweet mod! Or at the very least a quick release bowl so you can move it from low to high position.
Mod month hopefuls are jumping in the pool early.. good stuff
I got to work on this some more today. I realize I should probably name this thing as it's a keeper. Any ideas?
I started making templates to install the lower bowl daisy wheel vents. One interesting thing I noticed is that the WSM vent holes in the kettle are larger diameter than the holes on the vent. So I likely don't have to worry too much about the alignment tolerance for the 5 holes on a 22.5" wsm vents. I have a few old vents here that I'll use for test fitting but I'll likely order new ones so they fit nice and tight.
One thing that I test fit for today that I didn't anticipate is that the wsm charcoal grate is 18.5" and the performer charcoal grate is 17". Damn, more work to do. I'll do the math and figure out which diameter/height combo can hold the most charcoal. I'd be up for a taller, but narrower stack of charcoal if that means longer burn time and more consistent temps. I always find that the fire in the wide/shallow charcoal ring of the 22.5" wsm moves around and fluctuates the temp a bit. I'm also lazy and try to control the temp with one lower vent. :P My backup place is to drill new standoffs in the bowl to take the wsm charcoal grate.
Nice! Any chance of you wanting to sell the green kettle? I have an SS performer and the kettle has seen better days
Quote from: rmcmann on June 26, 2015, 09:03:26 AM
Nice! Any chance of you wanting to sell the green kettle? I have an SS performer and the kettle has seen better days
Thanks for asking but the dark green one is sold.
@pbe gummi bear, how's the progress on your WSM cart going? Any picture updates? ;D
This is awesome. I was thinking of getting an old genesis gasser table and turn it into a WSM table but this idea seems like alot less work.
After looking at your mod and planing to do it to my SS performer it seems like the wheels on my performer is the other way around compared to your's. Was this done on certain model year? But it kinda works for this mod since the ash can wont interfere with the axle for the wheels.
(http://i483.photobucket.com/albums/rr193/jaycee386/20150706_132247_resized_zpsifzmlype.jpg)
You should consider using a Hunsaker Smokers Vortex firebasket in your setup. You can cook hot n fast or low and slow. The basket for the Webers sit right on the stock charcoal grate. You can eliminate the WSM waterpan, and the One Touch vents would be a perfect fit for regulating intake.
Quote from: jaycee213 on July 12, 2015, 11:33:31 PM
After looking at your mod and planing to do it to my SS performer it seems like the wheels on my performer is the other way around compared to your's. Was this done on certain model year? But it kinda works for this mod since the ash can wont interfere with the axle for the wheels.
(http://i483.photobucket.com/albums/rr193/jaycee386/20150706_132247_resized_zpsifzmlype.jpg)
Nope......your SS Performer is assembled incorrectly. If it works for you as is, then I wouldn't mess with it, but it isn't "correct"
Quote from: OoPEZoO on July 13, 2015, 04:17:07 AM
Quote from: jaycee213 on July 12, 2015, 11:33:31 PM
After looking at your mod and planing to do it to my SS performer it seems like the wheels on my performer is the other way around compared to your's. Was this done on certain model year? But it kinda works for this mod since the ash can wont interfere with the axle for the wheels.
(http://i483.photobucket.com/albums/rr193/jaycee386/20150706_132247_resized_zpsifzmlype.jpg)
Nope......your SS Performer is assembled incorrectly. If it works for you as is, then I wouldn't mess with it, but it isn't "correct"
Good looking SS! Pez is correct though. The larger wheels opposing the handle allows you to "wheelbarrow" the cart around.
Quote from: jaycee213 on July 12, 2015, 11:12:32 PM
This is awesome. I was thinking of getting an old genesis gasser table and turn it into a WSM table but this idea seems like alot less work.
The Genesis frames are very narrow. They may fit an 18.5 inside but def not a 22.
Quote from: Bob BQ on July 09, 2015, 11:41:04 AM
@pbe gummi bear, how's the progress on your WSM cart going? Any picture updates? ;D
No major updates so far. Next thing to-do is place my vents.
Quote from: pbe gummi bear on June 13, 2015, 09:38:45 PM
This Green SS Performer is my Donor Cart. It's in great shape but Green is not my color
Well in that case
@pbe gummi bear are you planning on letting go of that limey in the back row ??? ;D ;D ;D SJ
Yes. It's taking up valuable space in my garage.
@pbe gummi bear Tell me more ... PM ??? SmokenJoe
Quote from: pbe gummi bear on July 13, 2015, 09:03:10 AM
No major updates so far. Next thing to-do is place my vents.
If you are going to Stokerize it why bother putting daisy vents on it?
@pbe gummi bear I tried this with one of my early Cajun Bandit builds. I had an OTS and I put WSM daisy vents on the bowl. They didn't conform to the OTS bowl and allowed way too much intake even closed.
Are you planning to use the LP charcoal starter as well?
Did you put the daisy vents in the same place as the wsm's? I rarely use my stoker but I would be interested in putting it on for wifi temps instead of blower control. Propane starter, yeah I'll give it a run. It would be nice to start up the fire right after reloading the charcoal. I think the fire starting at the bottom is superior to minion starting on top. Most of all I'm building this because it's fun and cool.
I've also thought about adding ot to my wsm bowl. Lol
Quote from: pbe gummi bear on November 03, 2015, 06:09:16 PM
Did you put the daisy vents in the same place as the wsm's? I rarely use my stoker but I would be interested in putting it on for wifi temps instead of blower control. Propane starter, yeah I'll give it a run. It would be nice to start up the fire right after reloading the charcoal. I think the fire starting at the bottom is superior to minion starting on top. Most of all I'm building this because it's fun and cool.
Yes, the daisy vents were at the same spot as a WSM.
Quote from: pbe gummi bear on November 03, 2015, 06:10:11 PM
I've also thought about adding ot to my wsm bowl. Lol
WOW! You don't strike me as a Hot 'n Fast cooker!
Quote from: swamprb on November 03, 2015, 07:48:17 PM
Quote from: pbe gummi bear on November 03, 2015, 06:09:16 PM
Did you put the daisy vents in the same place as the wsm's? I rarely use my stoker but I would be interested in putting it on for wifi temps instead of blower control. Propane starter, yeah I'll give it a run. It would be nice to start up the fire right after reloading the charcoal. I think the fire starting at the bottom is superior to minion starting on top. Most of all I'm building this because it's fun and cool.
Yes, the daisy vents were at the same spot as a WSM.
Thanks for the heads up. I'll pick up a contour gauge before I start drilling.
(http://pics.weberkettleclub.com/images/2016/03/26/image.md.jpg) (http://pics.weberkettleclub.com/image/u4)
Looks like Weber is commercializing my idea!
WTF are you gonna cook on it or take pics of it?? C'mon the suspense is killing me!
@pbe gummi bear
Quote from: swamprb on March 27, 2016, 07:57:59 AM
WTF are you gonna cook on it or take pics of it?? C'mon the suspense is killing me! @pbe gummi bear
Yeah, too many projects, not enough time. :(
Quote from: pbe gummi bear on March 27, 2016, 09:03:49 AM
Quote from: swamprb on March 27, 2016, 07:57:59 AM
WTF are you gonna cook on it or take pics of it?? C'mon the suspense is killing me! @pbe gummi bear
Yeah, too many projects, not enough time. :(
I hear that!!
@Kneab, in case you wanted to see more of this cart mod.
So I finished the bowl for this a few months ago by adding 3 22.5" daisy wheels near the original WSM locations. I say "near" because i moved one or two off to the side to clear the Gas Assist and frame. One stupid thing I didnt consider is that some vent holes hit the grate straps, soooooo those ventholes were fun to drill and grind round.
I also replaced the solid axle with 5/16" shoulder bolts and lock nuts to secure the wheels. Removing the axle makes it a little more wobbly but I don't anticipate moving this thing much.
So far this thing shares it's lid with my 22.5" WSM. These are the remaining components I need:
22.5" WSM lid
Charcoal ring
Water bowl/heat deflector- I'll probably just pick up an SS dish/bowl/platter from the restaurant supply store.
2005+ Performer Gas Assist regulator and hose
This is my only black 22.5" so I've used it for my KP so I don't craze my colored porcelain. It looks silly but works great.
(http://pics.weberkettleclub.com/images/2016/12/30/IMG_3493.md.jpg)
@pbe gummi bear !!! I've been waiting to see updates on this!! Love that you integrated the KP into it! Now how about some pics of it as a WSM...?
Thanks for bringing this post back up gummi. I am in the process of making a cart for my Smoky Mountain. But I was struggling with how to raise the shelf where my wsm will sit. Or if I will raise it. I never thought of moving the lower frame rails out to the uprights. It is perfect for what I want to do. I just haven't had the time to work on it this week. Hopefully I have the time to work on it this weekend. (https://uploads.tapatalk-cdn.com/20170113/4ca0f3e2954e16df0e504394474cd114.jpg)
The mock up so far.
searching for 1 18" straight lip twist ash pan.
Quote from: pbe gummi bear on January 12, 2017, 01:55:12 PM
@Kneab, in case you wanted to see more of this cart mod.
So I finished the bowl for this a few months ago by adding 3 22.5" daisy wheels near the original WSM locations. I say "near" because i moved one or two off to the side to clear the Gas Assist and frame. One stupid thing I didnt consider is that some vent holes hit the grate straps, soooooo those ventholes were fun to drill and grind round.
I also replaced the solid axle with 5/16" shoulder bolts and lock nuts to secure the wheels. Removing the axle makes it a little more wobbly but I don't anticipate moving this thing much.
So far this thing shares it's lid with my 22.5" WSM. These are the remaining components I need:
22.5" WSM lid
Charcoal ring
Water bowl/heat deflector- I'll probably just pick up an SS dish/bowl/platter from the restaurant supply store.
2005+ Performer Gas Assist regulator and hose
This is my only black 22.5" so I've used it for my KP so I don't craze my colored porcelain. It looks silly but works great.
(http://pics.weberkettleclub.com/images/2016/12/30/IMG_3493.md.jpg)
DAYUM! Is that pizza kettle built for Munchkins?? How long is the charcoal bin going to last with that setup? Do you have the 22" WSM lid and center?
I've got a Platinum frame I'm planning to drop the Chop Top Pizza Kettle into. Steel top is going to have to be ordered.