The Birth of a UDS

Uds

I had a barrel just like yours. If I had mine to do over I would have had the removable lid and lock ring be the bottom for easier clean out and cut the other end out for the top. A Weber lid fit perfect on the that end but I didn't realize that until I had already drilled the air intakes.
 
I picked up some of the materials I needed today for the charcoal basket. What is the best way to fasten the expanded metal ring to the charcoal grate?
 
I am on my second build,it is for a buddy of mine. They are fun to build no matter your skill level it will be enjoyable to eat good Q on something you did yourself. I was tired of looking for a weber top so I frankensteined another barrel and made an add-on. It seems easier to hold a constant temp than my original build,with the bonus of additional racks. Have fun and good luck.:thumb:
 
I just found, what I think to be, a pretty good deal on some expanded metal. A local steel shop sells 4'x8' sheets of the 3/4" 9-gage for $48 and they will cut it down to my specs for an additional $15. There would be enough area in a sheet that size to make quite a few charcoal baskets... :)
 
Awesome JM! I definitely gotta take a page outta your book and make a uds also. Love the meticulously laid out plan and step by step goals. Great job so far!
 
JMSetzler said:
I picked up some of the materials I needed today for the charcoal basket. What is the best way to fasten the expanded metal ring to the charcoal grate?
Click to expand...
I now weld them, but for my first one, I took thick wire and wire wrapped it to the grate. Still in use.
 
I found some threaded tube that was in the lighting dept. at Lowes for running wires in the top of ceiling fan etc. They came with nuts to tighten to the walls of the drum and protect my meat probes wire. I mounted it a couple of inches bellow grate level.:cool:
 
I moved a few more steps forward today on this project. I picked up a new $30 kettle grill at a place called "Big Lots". I am gonna use its el-cheapo grill grate as my lower grate for a diffuser and it's dome lid might just work out as my second lid for the UDS. I started flaring it out a little tonight and it's beginning to fit but it needs just a tad more flaring. Tomorrow or Friday I'll be picking up my expanded metal for the charcoal basket. Since I'm having to buy a 4'x8' sheet of expanded metal, I'll have enough to make six charcoal baskets with a smaller insert for each basket.

The basket I'm building will be using the charcoal grate from a Weber 22.5" kettle which measures 17" in diameter. I am gonna put an 8" ring of expanded metal around that which will be about 56" long to give me a couple inches of overlap. I'll also be making a 40" long smaller ring to use for shorter cooks since I'm having to buy so much expanded metal.

I went pilfering in my Dad's basement tonight. He said I could have all the nuts, bolts, and washers I wanted, so I now have some heavy duty 1/2" bolt legs on the charcoal grate...

Moving right along.... :)
 
I put the legs on the charcoal grate for the basket...

20110804_Basket_0430.JPG


This is a charcoal grate for the Weber 22.5" kettle. I pilfered my dad's nuts and bolts and found some SS 7/16 materials to use for this project...

20110804_Basket_0431.JPG


The bolts I had were only 1 3/4 long so I used a nut to fasten two of them together to extend the legs a little...

20110804_Basket_0433.JPG


I used a washer only on top and a washer with a lock washer between it and the nut on the bottom...

This configuration feels very solid and should last for a long time. I'll be picking up my expanded metal for the basket tomorrow...

I picked up an el-cheapo kettle grill last night to try the lid...

20110804_Drum_0434.JPG


20110804_Drum_0435.JPG


I flared the lid out enough to make it fit on top of the drum... I will clean it up and repaint it whenever I paint the rest of my parts...
 
Looking good so far!

I did a combination of flaring out the lid a tiny bit and grinding down the outer lip of the drum for a good fit.
 
As far as expanded metal goes. I went to a local welding shop and bought enough from him to build my basket. He even rolled it into shape for me all for the price of $10. If you got a welding shop around, it don't hurt to go ask
 
strawboss38679 said:
As far as expanded metal goes. I went to a local welding shop and bought enough from him to build my basket. He even rolled it into shape for me all for the price of $10. If you got a welding shop around, it don't hurt to go ask
Click to expand...

Thanks for the tip... I'll look around and see what I can find in the morning. That would save me a bit of money up front if I could find that...
 
I got my 48 x 48 expanded metal from Amazon for $27, including delivery. Just the right gauge for baskets...
 
JM - I am currently having a bunch of steel brackets fabbed up for UDS handles. My BGE handles will fit the bracket which can bolt to the drum or to the flat lid. Should have them finished up and on my Website early next week.
 
It's looking great so far. I can't wait to see it finished.
 
martyleach said:
That's a great price. I used 3/4 #9 for all my UDS's
Click to expand...

I was hoping to hear that. The place I talked to earlier this week sells that so it's most likely what I'm gonna get. I'm also gonna try something a little different for the assembly. I'm gonna try out some of the stainless steel zip ties to hold the expanded metal to the charcoal grate. I'm aslo gonna try using those to hold the expanded metal ring together. If it doesn't work I'll bolt them...
 
Jm,
That is the lid I used on barrel numbmer one. it works pretty well. I do like my weber lid for barrel two better because there is more room around the edges. The big lots lid hits on meat when placing meat around the outer edges.
 
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