Ever since seeing Robert-R's 26er cart on the Virtual Weber I've wanted to build something similar.
So I made a few drawings, found the pieces and went to work.
(https://lh3.googleusercontent.com/pw/ACtC-3dr0tlAlLH7Or48aO0OouVry-V-pADdlDFEA__gG9i_gpcXYlZrJfeuADxnV0fiBfxL1sGCvb27RR-iAEfwCwWLj9WqZUZ9mAaLhvFItk-yoEaoweC0uIK59v3g2oWDVtgBK2KuGk85CGVoNAH0lhSG0w=w1605-h903-no?authuser=0)
Front is going to have 3 30" wide baskets, two 7.5" tall and one 11.5" tall - all baskets are 14" deep.
(https://lh3.googleusercontent.com/pw/ACtC-3dalT9BTx1qBiFA8McAKkopPyLBH8oEbk10YYhu1Afk14RC6twHBhCYPgJHK79251_tvkwY6WtYKsz4pHOkmXNmFYP93gIkXoMzpyoUZx4EI0GZ3U2FgwIehZ7A9bjXJyxjyb6Ewm4I08vAN_b22DMXFw=w1605-h903-no?authuser=0)
Backside is going to have 2 18" wide baskets one 7.5" tall (for two charcoal chimney's) and one 18.5" tall for a bag of charcoal - again 14" deep.
Next to the baskets will be a standard 20lb propane tank for a flip up side burner for lighting my chimney's mainly.
Bought the metal from Speedy Metals which will cut your order to length within 1/8"- most pieces were cut exactly 1/8" long - once I evened out the cuts I went to work.
(https://lh3.googleusercontent.com/pw/ACtC-3ctpBohYQaKs9wcJkhVwfozk5fosdd2G4jZpOWWqgZoHjcx__4i6OPa-PbrNBQ3v9pfk3uJy1o0WOTdcNiyAFF9vqSxrCOaiOBP6Jo9vDKF0oB61usvgTWGpLxMk7m-q3rPuSn84tc0HLWWP4MKC3GUkw=w1605-h903-no?authuser=0)
Main structure
(https://lh3.googleusercontent.com/pw/ACtC-3cCKLLDbkWX9yXnHCuYXmgVcxuhIrM4lxoiHxlYv01wMopUJAyt3YdhJMvgfYp7pZG9un_Z3UnBwjTxNblgq1d4jhYg5zcbmBOqztEbnMfERE8NURKvUnGVaTSGPR-En5SQtpWFHDFLmS1O1o-TuLWQGQ=w1605-h903-no?authuser=0)
Spaced out and added the basket mounts
(https://lh3.googleusercontent.com/pw/ACtC-3fngoaYQFK8N8nASm1Lh9pL-sj0jpw9mgr-Mp5XxY1m9Mw0RLDrLhBfoOl70jIGBs2305Xx5IXws6vLhCuLc2lgqmkysG0zlDwSNILne8U1kZqy0kVGZODRlmGMrTApnImM1bx81tnhncizAnbvdLsuSA=w1605-h903-no?authuser=0)
(https://lh3.googleusercontent.com/pw/ACtC-3fh0b8gcHIoz1H1Dr5jMjeq-hJQGXmqxBTS2M4zddFzSemuLbt3OSUwgUJLgfcwf86QI9HH2kLKq_snYvzyV6B6r6DUKs5-YtzeOS2amVhgTHf6-OOtSCVGJkNFTrUHXkjOXFO3vmxeTO55ytQVh4prTQ=w1605-h903-no?authuser=0)
Added some handles/towel hangers
(https://lh3.googleusercontent.com/pw/ACtC-3dXjl0GTPtPNR9JMhaQzk_MsCt9t_k6d6_pLe4IYd_rb8Ox4UTw6yrOzrOcNvLqp3QsxsgshHx71JEeJ2-HSnypl9FRzpNrAzxEwb5IwYy3zM6beBNLQGPADWuksfVcNitQUUTY5dplzWfWIdVfPSTf1Q=w1605-h903-no?authuser=0)
Below the kettle shelf made of gas grill grates - cheapest way to cover that span in stainless steel - I was also off a bit on how wide the kettle and Unknown BBQ mounts were going to be so I had to add some standoffs - I also took the time to add a little height to the kettle so it mounts almost flush with the butcher block top.
(https://lh3.googleusercontent.com/pw/ACtC-3cP89jGi9U1duvAAIBBA0XzktHZoNAgk4oTK4ey3EUqwtEBu1gOPK3q5DzjRvNl-E334vVYNGQVW84lIxRXgV4jWIiyuhTE4Iry6CxthojQGf5fUtyM9q5vxxy3mmnLWlA1WC6C8_LnuKPEt2TjfqTYaA=w1605-h903-no?authuser=0)
Overall the cart is ~60" long - with the kettle, 50" long just the cart, 30" wide and once I add the 5" casters it should be about 37" high.
Wow that is going to be amazing. Strong work
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That is going to be sweet !! nice skills
@VetteDoc
Great fab work!! I am excited to see the final product.
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I'm looking forward to seeing the finished product! Nice nice nice
That's going to be nice, heavy and functional. Will it be graced with a Glen Blue 26"?
That's badass! Nice work. What welder are you using?
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Quote from: bamakettles on February 15, 2021, 05:10:29 AM
That's going to be nice, heavy and functional. Will it be graced with a Glen Blue 26"?
Nope - my AD code 26er will find a home in this bad boy
(https://lh3.googleusercontent.com/pw/ACtC-3ciigWtc8yA2YYzpyba_7uHM5hMnI8iVVFBKGCgOJ-FjkVhSCMVAADhXN1T1vfjV5k-C3Mqasd_AbSl6S7oN6G-0vTgXvD5bv9emga2Fn8bAJgEocFdkn5KOcibHSkkS5slXaK9bpIUnJHqlLSIgmx6Kg=w834-h625-no?authuser=0)
Here she is taking down my pellet cooker, this was the cook that really sealed the deal for me - (keeping the 26er and getting rid of the pellet cooker.)
More details on that cook here -
https://weberkettleclub.com/forums/index.php?topic=46402.msg459089#msg459089 (https://weberkettleclub.com/forums/index.php?topic=46402.msg459089#msg459089)
Quote from: HoosierKettle on February 15, 2021, 05:19:06 AM
That's badass! Nice work. What welder are you using?
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We just got a Miller Multimatic 215 at work and I wanted a little more practice with it so what better way than to build a grill cart?
Awesome job, what are you doing for a top...granite?
I'm looking forward seeing the finished cart.
Will you powdered coat the frame or use high temp paint?
Quote from: Tbagley on February 15, 2021, 01:48:48 PM
Awesome job, what are you doing for a top...granite?
I appreciate your advice in my previous thread but I'm sticking with the butcher block top - granite will definitely wear / weather better but I will be keeping the grill indoors when not in use and I just love the look and uniqueness of wood. I redid all of the wood on my Genesis 3000 and it just makes the grill.
(https://lh3.googleusercontent.com/pw/ACtC-3euaQOuTWPeVI4JP-g7dJvLAIVr1TM44A6JgyJ4HMz5E7S-th5GVNTFVPhCWgzh0nPJMza27nRkIiLx_cdxV7wsaFpVPrAB9R7kwQvSP4XfeXD7hq0aXusYaCv95DengWW6g7vrHZoy1lwHpL0RVPcXew=w1204-h903-no?authuser=0)
Quote from: AZ2FL on February 15, 2021, 02:02:47 PM
I'm looking forward seeing the finished cart.
Will you powdered coat the frame or use high temp paint?
Both actually - when I went to our local powder-coater they only had two red options and wanted an extra $200 to do color - so I'm going to have them coat it black then scuff it and paint it red - I did the same thing to the Performer I did for my dad on fathers day and I really liked the red/black contrast. Plus it will be easy to touch up any scratches down the road.
(https://lh3.googleusercontent.com/pw/ACtC-3eX_a497Dq4EpJj50fqgEmOUXn6weQ92r_O5eUAyyOjRyuaTW5_da-fFrKtSXge9v--qu3iHfXrVD_ra9LtoVkyY1W0Gl_3gvy7Ib7BiteX1NNrjBTagJcqSz4qFgjQKDS5S3utSpATDy6BhtD-4dG-iw=w678-h903-no?authuser=0)
I assembled most of the parts to verify fit before taking it in for powder-coating.
(https://lh3.googleusercontent.com/pw/ACtC-3eb-GsQM45lGdXEFqM7c5B6gOS-kssu9fSG7YYn0GzlgAaLVRrfQ5qmbn0RDIE7_1QqiueYdW0-MMY1ttVYv54KwLxYdta8U3j0qcM_AIGxsq249qH_jWhM0Ts6W7KvAZo8EQNFjJQuIfDxUMIN_cr-Dg=w1605-h903-no?authuser=0)
(https://lh3.googleusercontent.com/pw/ACtC-3euwPcJ72OR9XtQ5r96Qhfh3CiaYzntRjExu5vUQxyRfSyGsM530RzGG2dN9RS1oSUysAbZ4lu9xTprJmoKSKg32FRLwGUHzF0XPBJzk9ueZ2M5PVtvNRkKs5z2xd1j_m7XBF9yf11UruzvD0hp4Yz80g=w1605-h903-no?authuser=0)
(https://lh3.googleusercontent.com/pw/ACtC-3dgbWqrNiAr3znMDFDKCtdwitIWf9t2Q63C7-DZ1LxVcp4NQahGhLR2jAhzjlHFtsKaV6emM0gSf0lbW4NKHZ3TpZm2jPrm1uVZ0ZETPC9vBhgo1HaKpDjMaojjGE6WsNrld9NOXvv2hlA2QukmWJk8mA=w509-h903-no?authuser=0)
I ok I want to borrow your side burner info if you would be so kind, that would make a grate addition to my work in progress as I'd like to ditch my free standing propane burner. You sir are developing some welding skills!
Thanks! I'm getting better with the welder but at this point I think I'm still better at grinding than welding.
I actually stole the side burner off of my Saber 3 burner SS gas grill - a Weber chimney fits perfectly inside it. I have to cut a notch in the bottom of the chimney to get it to slide past the burner tubes but it works really well. I made a frame for the burner and made my own front panel out of SS - it's kind of a clunky set-up but it'll work.
If I didn't already own the gas grill I would've used a burner similar to what Robert R used in his cart.
VetteDoc thanks for the nudge, going have to search and see what I can find that may work. A folding burner plate would be cool but not a necessity.
That's coming together quite nicely. Looking forward to the finished product.
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Thanks guys, I'm finally starting to see the light at the end of the tunnel.
This came in yesterday from Forever Joint Tops - I'm doing 3 coats of Waterlox per their recommendation.
(https://lh3.googleusercontent.com/Oc_Ci0Pqw1_sGs_P92d8yNpc7_vrk6MvoQA_aLwyQEXX6zwNXdCRtXkaJ8T25tsKwNJvmV4J8OyvWKxi9NKB766NGUiaFWQ2OLtTAccl5rqYDd4RgtrnBJH7Y-5mIvSCCHsJb6nZkzBrZ-7D_FG1zh7C1v73bBex8mALKTKXHIDwq9boEQcSP-Vy-vF18PWKyZ1mDi4LFQoumnghfAEUxhzo577cudQBHj7K-jaoFdzpmyaqhLlm1Rlj75DJj2uQCF8fJvAzCfTzw1L0FQbxaMelQ6wWx3LAm_re62e7EDjayeG0z16-7joAQAe93kNESVtWHJncAryg1FNWlIwVlGNBx_Ob2cQpLlD4FnNAiPKcdSdCxIO18P--06xb2vUuI1EsZ31zuA5RWr6W2kERRmx5nKy72_390JkCPPpbVxFtCBjOFK7530rm_UDc45nP8hvz_VH1ri8Bg9svN6ZQBuVyy9EpIKb-NvGbXvR7Rh_0CRYqA8mWHidvysEJDo6YH-mZUJjKyzKpEIUpKmMRxMJ2-x2HRBW9ilYwduJpLEUuoTbKQDTCFlON0NlnRvXwwNmXsn3v0dNVu8aLpHhbtQAH84XYzHz3UrGhhxtMHk5rj887nKCNaD3K5PpR6eX0LZhhUXvntU0MJtaGnSLPAT9qPcT0AjIUFxvIi_i9NUfnOZprc_jTpjdRoXX9J74=w1112-h625-no?authuser=0)
The cart is going in for powder-coating today.
That top is beautiful
@VetteDoc
AMAZING.
I am beyond impressed. My knee jerk reaction is to ask you to make me one, but I know that the time, materials and labor involved are real and wouldn't expect that I could afford having something like this made for my slobbering self. If you were my neighbor, you would be showered with dry aged ribeyes, briskets and great bourbon and brews in silent hope.
As for the pellet vs Kettle test. I totally agree. The pellet smoker is no equal to smoking or cooking on a kettle with real wood and charcoal. I have every type of smoker ( I did give the electric smoker to my neighbor...) and I fully appreciate the convenience and ease of my pellet smoker, but the flavor from a kettle is unmatched dollar per value.
I will be watching this to the end!
Anticipation awaits seeing the powder coat! And holy smokes adding a side burner seems to be more of challenge than expected when trying to fugal, oh my they seem expensive.
Thank you for all of the compliments - I really appreciate the feedback - things are really starting to come together now.
I got the cart back from powder coating and I'm glad I decided to do the finish coating because there were some blemishes that would've bugged me - so here it is back from the powder-coater.
(https://lh3.googleusercontent.com/pw/ACtC-3cwkdsILDBiUI-x98McZvjDwyh2MhgV4QxKKzm25ggxorCj6iiSOZodXV5Qnp6u9atcXOd7ImwqxcxaQ0xk76pU35rsvaXtVawRO6MbCKsZqEq7UCBunQUe84k0vcxN8NRiq5ld6fQ3pt4SpJatxpjzQA=w1112-h625-no?authuser=0)
I roughed it up a bit with a scotch pad and wiped it down before giving it a 2000 degree primer coat.
(https://lh3.googleusercontent.com/pw/ACtC-3ev1-q55PWrUIYMnKLWRPt96WPDxZU3JdEjCxvbZTaDAZ0Emxdj2BTzKNolgIG1FyTAaV3qvsAUGv2Pm9TSgj46W08i1MOd_pv77Vi_uBsLoFrbnpXU4cdj1ilKmJurOZl2ZCOtVixjBC914qgWswlw-w=w1112-h625-no?authuser=0)
Followed by 900 degree brake caliper paint
(https://lh3.googleusercontent.com/pw/ACtC-3fGBxWFmd3wBlAwYwaBX4Uod4JZUP9oMbe7MUkDg7PHe_jzW8QA5P5AK5loFI0EEEAviMTm8lYSWkHgw9nzNsWxqw5Sy7rHIN2QAlKABNJm2xwmAj8zCWIElz7cX0h9ry3gAU5JgxADhJSKso_cMcs7bw=w1112-h625-no?authuser=0)
I'm hoping to do the final assembly Friday night.
Step by step it's nearing the end! Looking good.
(https://lh3.googleusercontent.com/pw/ACtC-3eg8xFm7dzcvb_idjz-KcA1St1CLMforJ-TwF0-1W_lSQcaQDacvcrdpTVd3i2xzsyLeEjQxBb1a9Z8M70S8ghaRPetdKphHGa7ZPQf8-_63c-VMGC7aTXHJnAqUIhAtxdR4odQ905oE2Om9THnZtC6Dg=w1605-h903-no?authuser=0)
(https://lh3.googleusercontent.com/pw/ACtC-3dJrZL6U94OCkRsiIikOK4z2VLPvmh2PlXzjzSKNXlx1RUQEl6TewLguCbOrG48WIUE9Q-kQ37FMbunwImt3BJdMvnyh-nqky5sZGRRUcF_5wNBleR0HzLVubje9ggJq_-peNBYig703zCJIU-bR3WqfQ=w1605-h903-no?authuser=0)
(https://lh3.googleusercontent.com/pw/ACtC-3fZX-zTS9Nrhy7AQ33EN40K-hIybpVqgcTvOGJjv16Ki0eljBU_1YcTZuqeUCyVkms9RxS-H72n8F2Quk7My_YNSZgTpheXQBmuz8BgB_IZYLICcsEUpy8X8n374n7hZItmFm5jhqChiYESBrUTrCHPig=w1605-h903-no?authuser=0)
Finally got it assembled - I still have a few tweaks to make but cooked up a couple of steaks last night that turned out great!
(https://lh3.googleusercontent.com/pw/ACtC-3cLpIfy24Js5DBlt2a8sdmbBZzP8R8W6jW53LhzRDBL0FbSXM9RYgID8GK4VGL0OM3WPqTs_ZOnddHZ4-NqCZTxyhSv2VX0UxepH20l6hl0hhH3ugOylFEJ7rne0sVf9rvGqbR0uvFvuRzvH0nEYTCk8g=w1605-h903-no?authuser=0)
Slick

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WOW!
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Beautiful
Grate work
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Amazing! Excellent work!
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Professionally done!
Excellent craftmanship !!
Looks really nice!!! Good job!
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Really nice job!! Impressive!
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Thank you everyone!
I'm really happy with the way it turned out, for anyone who wants to see some more detailed pics see the link to the build gallery below:
https://photos.app.goo.gl/4tMZpVzGm5axDrD1A (https://photos.app.goo.gl/4tMZpVzGm5axDrD1A)
This is truly a work of art. Very impressive
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Amazing!
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Dang
I would have to pay someone to do that

Great job and thanks for sharing!
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Looks really great all put together. I love the flip down burner too.
Nice job! you're very talented.
Just wanted to bring this back up with some "lessons learned" if I were to do it again - I would not do a butcher block top. When firing up the chimney I have to cover the top with a welding blanket to keep it safe. A stainless or stone top would be a better option.
That being said everything else has worked out to plan and I'm loving it.
Here it is rolling smoke on a couple 10 lb pork butts.
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Great job! It looks fantastic.
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I like it
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If I could insert a gif, I'd insert the "we're not worthy" scene from Wayne's World. This is awesome
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Kudos!!! Nicely thought out & finely crafted. They get BIG, don't they?
Quote from: robert-r on May 29, 2022, 03:05:56 PM
Kudos!!! Nicely thought out & finely crafted. They get BIG, don't they?
I would say the same about your XL - thank you for the inspiration. After all - "imitation is the sincerest form of flattery."
It is the most convenient cooker I could ever want - IMO
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That looks great!
The size,the colors, storage(that you can never have to much,every home owners knows this) and finally the craftsmanship.
Very well done, kudos to Robert for the inspiration.
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VetteDoc, awesome build, with some of your inspiration I finally got around to replacing the top on my cabinet so the black starboard is gone and granite was its replacement. Wish I had a piece of granite that was a 6 or so inches longer I would have cut it slightly different but the stone was a gift.
From this
(https://i.imgur.com/gYZgst3m.jpg)
To this granite top
(https://i.imgur.com/HPQVxT6m.jpg)
Quote from: VetteDoc on April 30, 2022, 12:13:57 PM
Just wanted to bring this back up with some "lessons learned" if I were to do it again - I would not do a butcher block top. When firing up the chimney I have to cover the top with a welding blanket to keep it safe. A stainless or stone top would be a better option.
That being said everything else has worked out to plan and I'm loving it.
Here it is rolling smoke on a couple 10 lb pork butts.
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I love the look of the butcher block. When I fire up my chimney starter, I just put it on the cooking grate of the kettle. That way ash fall where it needs to fall.