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Q-talk *ON TOPIC ONLY* QUALITY ON TOPIC discussion of Backyard BBQ, grilling, Equipment and just outdoor cookin' in general, hints, tips, tricks & techniques, success, failures... but stay on topic. And watch for that hijacking.


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Unread 03-23-2010, 11:54 AM   #1
Rodney
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Default UDS charcoal basket "how I built it" video

Hey everyone-

Using an upside down clamp light on a 55-gallon drum as a tripod for my iPhone 3GS, I recorded the process of building my charcoal basket. Notice I said "how i built it" and not "how-to", because I'm sure there are better ways of doing it. Anyway, here's the link:

http://www.youtube.com/watch?v=bCyKypslPhs (480p resolution! Sweet.)

First off, sorry for the low volume level... Gonna have to turn your speakers up a bit to hear what I'm saying.

Some thoughts:

- The last 4" or so of the expanded sheet is difficult to bend when holding it down with your own weight. It was difficult for me, and I weigh 255! Finding a different way to clamp it down would be best, or just use the hammer method all the way around (although it won't come out as smooth unless you're good with a hammer). Using the thinner stuff from Home Depot would be much easier, but may not last as long.

- I think it was easier starting with a 2' square sheet, cutting it into 8" x 24" pieces, and bending the wall of the basket in two halves. Bending by this method with a 48" piece would've been a major pain in the butt.

Other comments are welcome!

-Rodney
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Last edited by Rodney; 03-23-2010 at 12:37 PM..
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Unread 03-23-2010, 12:12 PM   #2
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Cool video. I did mine by bolting the two pieces together and laying them flat on the floor. I then stood the grate on it's side right in the middle at one end and just rolled it by hand. Your way would have probably been easier.
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Unread 03-23-2010, 12:24 PM   #3
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Quote:
Originally Posted by Cre-B-Ce View Post
Cool video. I did mine by bolting the two pieces together and laying them flat on the floor. I then stood the grate on it's side right in the middle at one end and just rolled it by hand. Your way would have probably been easier.
Thanks! Were you using 9-gauge material? If so, you're strong! ;-)
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Unread 03-23-2010, 12:32 PM   #4
Paulmark
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Very good video, thanks
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Unread 03-23-2010, 12:50 PM   #5
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Great video wish I knew how to weld
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Unread 03-23-2010, 01:00 PM   #6
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Nice vid!
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Unread 03-23-2010, 01:06 PM   #7
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Quote:
Originally Posted by Alan in Ga View Post
Great video wish I knew how to weld
I'm really not good at it, and this was great practice. It's nice when something doesn't have to be pretty... ;-) That said, this thing could be built with wire just as easily (I imagine some 304 stainless TIG welding rods, .050" diameter or so, would probably be decent wire to use)... Just gotta twist the wire nice and tight with pliers so it's not rickety!
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Unread 03-23-2010, 01:58 PM   #8
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I left you a comment over at the youtube Bro' Great Video...Did that Dog stay out the way?!! LOL...Peppa
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Unread 03-23-2010, 02:05 PM   #9
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I fasten mine with, what else....hog rings.
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Unread 03-23-2010, 02:17 PM   #10
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Quote:
Originally Posted by peppasawce View Post
I left you a comment over at the youtube Bro' Great Video...Did that Dog stay out the way?!! LOL...Peppa
Thanks! Yeah, she stayed out of the way... at first, she wanted to hang out with me, until I started the cutoff saw. You might notice that when I was cutting the second piece, she was way off in the background. I put her in her kennel before I welded so I wouldn't burn her eyes.

I'm getting more and more southern... My dog is a Catahoula Leopard Dog mix (a hog-hunting breed native to Louisiana, her name is Roux... get it? ) and now I have a smoker and am gonna be making fatties and ABT's, neither of which I'd heard of before joining this forum. My friends and family will be very familiar with BOTH very soon.

-r
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Unread 03-23-2010, 02:19 PM   #11
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Quote:
Originally Posted by expatpig View Post
I fasten mine with, what else....hog rings.
Good call. Hog rings seem to be one of those must-have fastening methods like duct tape and zip ties, but I don't have the rings or the pliers. I should change that.

-r
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Unread 03-23-2010, 02:22 PM   #12
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I loe the fact that you left in the parts where you had to rethink what you were doing. That is really helpful! Good job.
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Unread 03-23-2010, 03:21 PM   #13
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Great video!
I've built a number of UDS's and baskets and have found that if you cut the expanded metal the other direction (diamond pattern up and down rather than horizontal) it is much easier to form/roll...and if you're building a number of them and get a 4'x8' sheet of expanded metal, you can get 8 pieces 12" in height out of it and I use the charcoal grate for the 18 1/2" Weber rather than the grate for the 22 1/2" Weber...I built my first couple of baskets using the 22 1/2" charcoal grate, but felt it was too wide in diameter wasting fuel and space and always ended up using a piece of expanded metal to block 1/2 of it off.



This was my first basket that I built back in 08 using the charcoal grate for the 22 1/2" Weber...and it shows the expanded metal piece I inserted to make it's capacity smaller
I don't have any pron of my new style baskets with the vertical diamond pattern or the charcoal grate for the 18 1/2" Weber... but will get some up soon.
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Unread 03-23-2010, 04:07 PM   #14
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Now I feel stupid. ;-) I did so much thinking ahead of time about how I wanted to build my UDS, but didn't even THINK about cutting the expando one way or the other... I just started marking and cutting. Of COURSE it's easier to bend in the other direction! How much easier? Well, I just happen to have the tools in front of me to figure it out... LOL...

So, here I go with a major egghead move:



This model shows two pieces of expando with one edge magically glued to a wall and 20 pounds hanging off of the other end of the piece, and the displacement numbers show how far the end of the piece sags under load. It turns out that expando is 5.2 times stiffer (and therefore stronger) if you try to bend it the way that I did. In other words, BEND IT THE OTHER WAY!

I knew it shouldn't be as hard as it was, but I didn't know I was doing 5 times as much work as I had to!!!

So, now that you all have seen me wrestle with that expando, you know what NOT to do. Glad I could help.

-r
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Unread 03-23-2010, 04:13 PM   #15
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Don't feel stupid...I built 2 before I figured it out...
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