BobM
Babbling Farker
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.
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.
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