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Unread 03-02-2013, 09:02 PM   #1
Babbling Farker

Join Date: 02-16-12
Location: Long Island, NY
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Default WSM Middle Handle Mod (pr0n)

Another intrusive WSM mod!

The factory WSM handle metal is 9/16" x 1/16". The closest I could easily find was 1/2" x 1/8" flat stock at Lowes. I bought 3 - 3 foot pieces, 1 piece for prototypes and 2 pieces for the finished product.

My first attempt was a failure, but I got data. The second attempt was close and needed only a little tweaking to get it right.

I bent the pieces in a 4" bench vice. The final measurements I used, from the end in are:
1st bend: 2"
2nd bend: 1 3/4"
3rd bend: 3 7/8"
4th bend: 1 5/8"

1st successful bend, using my 22 1/2" WSM side handle as a template.

I replicated the prototype bend on the next two pieces of flat stock.

Cut up, drilled and sanded, including the prototype.

Painted black.

To match my 22 1/2" WSM, I got 2 dark gray handles from Weber.

To match my 18 1/2" WSM, I got 2 light gray handles online.

To fit my custom metal work, I had to round off the corners, and flatten the back of the light gray handles with a belt sander.

I mounted the handles with 10-32 x 1/2" stainless steel screws. I then cut the extra threads with a bolt cutter and filed them down.

The 18 1/2" WSM

The 18 1/2" WSM, closeup

The 22 1/2" WSM.

The 22 1/2" WSM, closeup.

The 22 1/2" WSM, showing my other mods.

The pair.
"Beer is living proof that God loves us and wants us to be happy." - Benjamin Franklin
| Weber 18 1/2" & 22 1/2" WSM, 22 1/2" & 26 3/4" OTG, Genesis S-330 |
| BBQ Guru CyberQ WiFi
| Maverick ET-732 |

Last edited by BobM; 03-02-2013 at 09:32 PM..
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