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-   -   Ranch Kettle Restoration. (https://www.bbq-brethren.com/forum/showthread.php?t=108452)

Q-Dat 06-09-2011 10:43 PM

Ranch Kettle Restoration.
 
5 Attachment(s)
Ok looks like I have some work to do. Overall the grill is in pretty decent shape, but there was a pretty rusty area on one side that I have already cut out.

Attachment 53710
Attachment 53711
Attachment 53712
Attachment 53713
Attachment 53714

Any suggestions on patching this?

deathamphetamine 06-09-2011 11:07 PM

... weld in a patch.

tommykendall 06-09-2011 11:28 PM

holy crap

Q-Dat 06-09-2011 11:38 PM

It really won't take too much doing. Just need to get a piece of steel the right thickness.

CarolinaQue 06-09-2011 11:49 PM

You know how to TIG? Stick welding will blow right through that.

Q-Dat 06-09-2011 11:52 PM

I dont. My Brother in law can, but I may end up brazing it.

Smoked 06-10-2011 12:19 AM

Is it still under warranty...give Weber a call...:pray:

Q-Dat 06-10-2011 12:23 AM

Quote:

Originally Posted by Smoked (Post 1669890)
Is it still under warranty...give Weber a call...:pray:



I certainly wish!

martyleach 06-10-2011 12:24 AM

Jeez, that all looks pretty thin. Good luck welding or brazing that.

redvert05 06-10-2011 12:35 AM

I had to go the route of 600* rated JB weld to re-inforce areas of a Red Kettle I just restored. I have ran it hard for a few hours and all the areas seem to be holding. So you may consider using it or similar to affix the patch panel in place if the metal proves to thin to weld.

Igotgas 06-10-2011 03:22 AM

I think Tig is the way to go vs JB weld if you have the choice. Stitch welding it with a tig will keep the metal from tweaking while you weld. Maybe your Brother in law would be up for some q in exchange. Kettle metal is pretty thin, but I think it will be an easy fix for you if you can tig it. I definitely will be following this one:thumb:

che22879 06-10-2011 03:49 AM

Hope you get it fixed up with out any problems!

Q-Dat 06-10-2011 02:29 PM

Just dropped it off the the BIL. As it turns out he does not have a TIG setup like I thought. It's all good though he's got a flux core that he says he can do it with. He's been building cranes for 20 years welding every thickness of steel imaginable so if he says he can do it then I believe him.

He's gonna cut out a piece of 1/8" plate the size of the hole and weld it in. Then I just have to cut in the new vent holes and make some aluminum daisy wheels and I'm in bidness!

redvert05 06-10-2011 02:51 PM

Call Weber CS and inquire on the cost of a "damper kit" for it. I bought one a kit for the Red Kettle I restored. $5.60 for all 3 dampers and hardware with free shipping this month. I was going to make one for mine as well until I called them! Only thing is, those new dampers have a AA date code on them....and the kettle of mine is pre 79 with no date code! That will confuse the crap out of someone someday when they look at it! :heh:

Q-Dat 06-10-2011 05:26 PM

Quote:

Originally Posted by redvert05 (Post 1670416)
Call Weber CS and inquire on the cost of a "damper kit" for it. I bought one a kit for the Red Kettle I restored. $5.60 for all 3 dampers and hardware with free shipping this month. I was going to make one for mine as well until I called them! Only thing is, those new dampers have a AA date code on them....and the kettle of mine is pre 79 with no date code! That will confuse the crap out of someone someday when they look at it! :heh:

Haha it probably will, but the heavy steel plate on the bottom should explain things.

jestridge 06-10-2011 10:34 PM

The best way to repair that is pop rivets, if you weld a new plate in the chances arit will rust back out here it been weld .you could braze it but prolly wouldn't look that good, don/t think flux core will work..

Q-Dat 06-10-2011 11:14 PM

Well he's already done. I figured it would be a day or two before he got to it but he cut the plate and welded it on this afternoon.

I'm picking it up in the morning. I'll post pics of the repair.

You can tell by looking at it that the only reason it ever rusted in the first place was neglect. There was old ash piled up in it from no telling how long ago. If cleaned out regularly the Weber porcelain coat can take a ridiculous amount of use.

PorkDork 06-10-2011 11:26 PM

I think the best (and easiest) way would be to find a piece of sheet metal larger than your hole and just use some small screws to screw it on there.

Q-Dat 06-10-2011 11:47 PM

Quote:

Originally Posted by PorkDork (Post 1670844)
I think the best (and easiest) way would be to find a piece of sheet metal larger than your hole and just use some small screws to screw it on there.

Already welded.

Q-Dat 06-11-2011 02:14 PM

2 Attachment(s)
Ok here is the patch.

Attachment 53782
Attachment 53783

His grinder died on him so I'll have to finish dressing it up but he did good!

Next I'm gonna fill the remaining pits on the inside by brazing.

Smokin Turkey 06-11-2011 02:55 PM

You forgot to cut the vents in!

jestridge 06-11-2011 03:10 PM

Not bad , actually lot better than I expected , need to finish grindering it with a smooth wheel

Q-Dat 06-11-2011 03:19 PM

Quote:

Originally Posted by Smokin Turkey (Post 1671328)
You forgot to cut the vents in!



DOH!!! Haha I'm gonna use a step bore bit for that.

Q-Dat 06-11-2011 05:05 PM

Quote:

Originally Posted by jestridge (Post 1671337)
Not bad , actually lot better than I expected , need to finish grindering it with a smooth wheel



The impressive thing is that he didn't even use flux core. It was just steel wire.

Q-Dat 06-11-2011 11:02 PM

Ok here is the plan. Sandblast the pitted area on the inside until it is totally clean. Then use a rosebud torch and brazing rods to tin over the whole entire rusted area.

Anyone see a reason this won't work? The goal is to completely cover any bare steel on the inside.

Q-Dat 06-12-2011 06:21 PM

1 Attachment(s)
Ok I'm still gonna sandblast, but now instead of brazing I'm gonna use this to fill in the pitted area.

Attachment 53837


Its good to 2400* and is safe for use in grills. I got it at Pep Boys.

BBQpower 06-12-2011 06:30 PM

For some reason tin sounds a lot better. test some of the stuff first, burn it and see if any smoke or foul smells come off of it. I am still wondering who picked up the ranch kettle from San Mateo on CL for $100 ??? Was this you?

AJP 06-12-2011 06:34 PM

Looks awesome can't wait to see how this ends.

Q-Dat 06-12-2011 06:42 PM

You actually have to cure it with high heat. I'm sure there will be some fumes during this process.

I found an MSDS for it, and it only contains steel dust, magnesium silicate, and sodium silicate. None of which should be harmful. However, you can bet my nose will be at full alert in case anything weird comes off of it.

This stuff could be the answer to alot of pit repair issues out there.

Q-Dat 06-12-2011 06:46 PM

Quote:

Originally Posted by BBQpower (Post 1672241)
For some reason tin sounds a lot better. test some of the stuff first, burn it and see if any smoke or foul smells come off of it. I am still wondering who picked up the ranch kettle from San Mateo on CL for $100 ??? Was this you?



Nope I'm in Southeast Louisiana. But that is an even better deal than mine. I paid $200

BBQpower 06-12-2011 06:51 PM

Thanks for the answers Q, and yes and can't wait to see it burning again!:thumb:

Q-Dat 06-12-2011 10:12 PM

Any suggestions for what to cook first when I get it finished? What does this baby do best?

BBQpower 06-13-2011 08:12 AM

I say so some indirect cooling on it!
Make a RACK OF BEEF RIBS & a FATTY!:-D

Groundhog66 06-13-2011 02:34 PM

Quote:

Originally Posted by Q-Dat (Post 1672500)
What does this baby do best?


About 100 hamburgers :heh:

Q-Dat 06-13-2011 03:00 PM

Quote:

Originally Posted by BBQpower (Post 1672567)
I say so some indirect cooling on it!
Make a RACK OF BEEF RIBS & a FATTY!:-D



If I can find some Beef Ribs that actually have some meat left on em I might just do that.

Q-Dat 06-13-2011 03:02 PM

Quote:

Originally Posted by Groundhog66 (Post 1672674)
About 100 hamburgers :heh:



Actually its gonna get used to grill chicken and sausage for our Church's 25th anniversary dinner this coming Sunday. So it will be getting a workout.

Igotgas 06-13-2011 04:27 PM

Quote:

Originally Posted by Q-Dat (Post 1672500)
Any suggestions for what to cook first when I get it finished? What does this baby do best?


They Really Love Tri Tip

http://i1126.photobucket.com/albums/...e/IMG_0447.jpg

And Chicken

http://i1126.photobucket.com/albums/...e/IMG_0449.jpg

Q-Dat 06-14-2011 12:26 AM

Quote:

Originally Posted by Igotgas (Post 1672825)



Nice! I haven't cooked tri tip before. I might have to get one of the cutters at the store I work at to set me some aside. Around here they get cut up for stew meat believe it or not.

LoneStarMojo 06-14-2011 12:51 AM

Quote:

Originally Posted by Q-Dat (Post 1669893)
I certainly wish!

That sucker comes wid a 10 year warranty Bro. Give it a try. Couldn't hurt.

LoneStarMojo 06-14-2011 12:59 AM

By the way...nice lookin feast...I guess things are different down there cuz that did not look like my tri-tips....different butchering I guess.

Q-Dat 06-14-2011 12:59 AM

Quote:

Originally Posted by LoneStarMojo (Post 1673372)
That sucker comes wid a 10 year warranty Bro. Give it a try. Couldn't hurt.



I'll look for the date code on it. If its less than 10 years old I'll give them a call. You are right though. The worst they can say is no.

Q-Dat 06-14-2011 01:02 AM

Quote:

Originally Posted by LoneStarMojo (Post 1673375)
By the way...nice lookin feast...I guess things are different down there cuz that did not look like my tri-tips....different butchering I guess.



Those were the Tri-tips of Brother Igotgas. I have never seen one for sale in a meat case here.

LoneStarMojo 06-14-2011 01:02 AM

This site will sell you a new kettle bowl cheap! NOT!...lol

http://www.appliancefactoryparts.com...ber-60020.html

LoneStarMojo 06-14-2011 01:04 AM

By the way did you see my King Kettle score of Kansas City CL...I got damn lucky for 300 bucks.

Q-Dat 06-14-2011 01:06 AM

Quote:

Originally Posted by LoneStarMojo (Post 1673384)
By the way did you see my King Kettle score of Kansas City CL...I got damn lucky for 300 bucks.



Yes I did! That was a really sweet deal. I had never heard of Whalen. Sounds like Weber's Lawyers ripped them a new one and they never recovered.

LoneStarMojo 06-14-2011 01:09 AM

Quote:

Originally Posted by Q-Dat (Post 1673388)
Yes I did! That was a really sweet deal. I had never heard of Whalen. Sounds like Weber's Lawyers ripped them a new one and they never recovered.

I think Whalen has always been big on making fire pits and kind of stepped out of their element and accidentally stepped into something else....lol.

PaddyKC 06-14-2011 02:15 AM

Quote:

Originally Posted by martyleach (Post 1669895)
Jeez, that all looks pretty thin. Good luck welding or brazing that.

Marty, it seems like your always around to lend a kind helpful and encouraging word to your fellow BBQ Brethren.

Q-Dat 06-15-2011 11:30 AM

6 Attachment(s)
Ok got the inside rusty area cleaned up and filled in with Thermosteel. Also got the new intake holes drilled.

Attachment 53934

After the stuff set overnight, I built a small fire out of Oak limbs from the yard.

I put the cooking grate and the lid on and let that burn for a while until I was confident that it was fully cured, and any fumes were gone.

Attachment 53936

Not being one to waste a good fire I grabbed a can of Spam and cut it into four squares and seasoned with a little Black Pepper. Grilled em up nice and quick along with a hotdog for good measure.

Attachment 53937
Attachment 53939

Then enjoyed myself a nice Spam n Cheese Sammich!

Attachment 53938

It seems like the Thermosteel has done the trick. Hopefully it will be a lasting repair. This grill will definitely get cleaned out after every use!

Now I just need to make or buy my new Daisy Wheels for the intakes, do a little cleaning and touch up painting and I'm done!

deguerre 06-15-2011 11:35 AM

You've really done a great job on that and the welder really showed some stuff too.:thumb::thumb:

Q-Dat 06-15-2011 12:16 PM

Quote:

Originally Posted by deguerre (Post 1674961)
You've really done a great job on that and the welder really showed some stuff too.:thumb::thumb:



Thanks. He really is good. First I thought he was gonna TIG it. Then I found out he doesn't have one. Then I thought he was gonna use flux core, and found out he didn't have any flux core wire.

He actually welded that thin metal with plain old steel wire!


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