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[toolhead]

Theres a way to mod the 7444 ash sweep for 1st gen ash can setups.


I did a writeup on this and anither memebrr uploaded my schematics
Its super simple..just takes a little time and metal file

[PotsieWeber]

I just found this thread today on one @greenweb did by bending the old ash can cross bar so it is flush with the kettle & deleting the H washer.  A couple posts later, he mentions using a ss washer to keep the bar in place.

I think I ran across some references to your method @toolhead, but did not run across a decent explanation of it.

[toolhead]

Did you see the schematics upload post?

[PotsieWeber]

I didn't find any schematics. 

But, one of the links I included has a post by @addicted-to-smoke that says "The 7444 sweeps come with a washer that’s too thick to replace that ash bar. OR, if still good, retain your ash bar AND use the new 7444 sweeps by taking a round file to the two holes that the sweeps’ lever passes through and it’ll install OK. Some trial and error is needed here. Hat tip to @toolhead for that mod."

Did you see the schematics upload post?

[toolhead]

 @PotsieWeber

Let me know if this link works for you..

Its super simple...i figured it out years ago...just need circular metal file
 http://weberkettleclub.com/forums/weber-kettles-accessories/solving-the-7409-ash-sweep-problem/msg301142/#msg301142

[toolhead]

I just linked you..that thread has my schematic.

Toss the h washer its useless..

Just get a file and check your work.

If you open the hole too much its too loose..you want it snug.

Test fit first.. try to slip in the handle...mark with sharpie where its hitting so you can eyeball clearance required.
Then stop short of clearance and test fit.

Remember you have to file both drop points of the ash sweeps..so you have 2 holes to file down

[PotsieWeber]

Thanks for the link.

[PotsieWeber]

One more questions, @toolhead.  When you do the filing you suggested, do you have to bend the bar or not?

[toolhead]

? You only mod the ash sweep.

Look at it this way.

The problem is that the holes dont accept the 7444 ash sweep

Solution: open up the holes

Thats all thats required.

If you ash bar is deformed its a good time to bend it back into shape.

A lot of the original bars are bent due to rust and water weight in the pan weighing on the bar and deforming the bar so the pan sits low.

Let me know if you need more help...

Budget about 1 hr for the mod...filing the holes takes some sweating ..

Im about to post an aluminum ash  catcher bar that i fabricated myself in the sale forum, given this thread is reminding me i have a spare in my weber parts box lol

[toolhead]

If you dont have a metal file set.

Hdepot or lowes..
I have a kobalt set i bought for 29.99 ten years ago ..comes in handy..just used it to sharpen 4 lawnmower blades this past weekend.

[PotsieWeber]

@toolhead

So, you throw away the h washer

You open up the two holes in the finlike projections that fit through the h washer

My understanding is you are opening up the hole enough for clearance of the ash can retaining bar thing (so you don't have to bend it down towards the kettle, like one of another solution).

I assume you use the new sweep handle, not the old one or is it vice versa?

I've picked up files dirt cheap at garage sales over time.  I should have something that will work.

[toolhead]

Toss H washer or toss them in a bin....i have a pile of them lol.

I think this will help

Wipe out any prior mod you read about

Then take a look at the schematic

My mod is a solution by itself and requires no other mod to be combined with it to work

The h washer itself is what it is..its a washer so the ash handle has a clean rubbing surface

Old model cans simply used the ash catcher bar as both a washer and bracket to hold the ash ring

If you are modding a 7444 to the old ash cans...your ash catcher bar replaces the h washer.

The problem with 7444 working with older ash cans is that the h washers are thinner then the old ash catcher bar so using a 7444 ash sweep with older ash catcher bar...the ash sweep bar wont fit into the holes...(also your old bar is probably a little bent which makes the tolerances even worse)

Open up the holes and the problem is solved.

I think once you get in front of this at home..this will make a lot of sense.

All that said..the flat part of your ash bar that mates against the bottom bowl (has holes in it).

This one inch middle section should be flat....its probably bowed downwards a but from weight of holding ash pan for years.

Take a hammer and hammer the one inch middle section straight.

Your ash pan will sit tighter /flush like when it was new and it will also be less filing for you

[toolhead]

The link i sent you shows my redhead with the aluminum ash catcher bar/7444 modded and show the ash pan assembly nice and snug against the bowl like it should be

[PotsieWeber]

By the way @toolhead, I tried it & it worked out fine.  I did it with a stainless set of ash sweeps, so I should never have to deal with it again.

I was thinking about trying to open up the hole a bit more to accommodate the h-washer, in addition to the bar, just to prevent the handle from revolving.  But it seems in there pretty tight already, where you can revolve the sweep handle if you want to, but it is not really going anywhere.  So, I decided to heck with it.  I take it that is how you leave it @toolhead.

[toolhead]

F the h washer it useless lol.
I have a pile of them in my parts bin
Glad to hear it worked out for you

Keep in mind...stainless steel is rust resistant ..not rust proof

Also pending the grade ss


Im pretty sure weber aint offering 300 series grade ss in their ash sweeps
Add in the corrosive element of charcoal ash with food drippings n heat...the SS sweeps will rust out eventually.

Tho they will weather better than the aluminized sweeps.