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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 03-02-2013, 09:02 PM   #1
BobM
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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.
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Last edited by BobM; 03-02-2013 at 09:32 PM..
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Unread 03-02-2013, 09:29 PM   #2
Dirtbuddy
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Nice work Bob!
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Unread 03-02-2013, 09:33 PM   #3
HeSmellsLikeSmoke
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They sure do look official.
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Unread 03-02-2013, 09:35 PM   #4
Hoss
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Sweet mod!
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Unread 03-02-2013, 09:37 PM   #5
Big M1ke
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I likey
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Unread 03-02-2013, 09:39 PM   #6
nucornhusker
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They look great. I've always wondered why they weren't on there already.
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Unread 03-02-2013, 09:39 PM   #7
Bluesman
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First class job, nice attention to detail............
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Unread 03-02-2013, 10:02 PM   #8
Bob13
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Looks spot on... great job!
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Unread 03-02-2013, 10:09 PM   #9
HankB
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Thanks for posting the info.

Quote:
Originally Posted by nucornhusker View Post
They look great. I've always wondered why they weren't on there already.
Liability. Weber does not want you moving the middle sectoin and possibly spilling boiling water during a cook.

For the OP, can you tell me what the distance is between the screw holes? I was thinking about mounting a couple handles on my 22.5 WSM vertically on the outside where the inside brackets mount. My thought is to use the existing top hole for the top end of the handle and add a bottom hole for the handle that would also provide support for a third grate in the WSM. That would work if the distance between screw holes is about the same as half the distance between grates.

Do the covers still fit?

thanks,
hank
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Unread 03-02-2013, 10:54 PM   #10
nucornhusker
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I personally wouldn't run one with water so I never would have thought of that.

Thanks.
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Unread 03-02-2013, 11:09 PM   #11
BobM
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Quote:
Originally Posted by HankB View Post
Thanks for posting the info.
You are quite welcome, I hope it was helpful!


Quote:
Originally Posted by HankB View Post
Liability. Weber does not want you moving the middle sectoin and possibly spilling boiling water during a cook.
I don't use water in my WSMs and I would never consider moving the cooker in the middle of a cook.
The handles make the WSM much easier to move, especially the 22 1/2" model.


Quote:
Originally Posted by HankB View Post
For the OP, can you tell me what the distance is between the screw holes?
For the handles I made, 5 5/8", center to center.


Quote:
Originally Posted by HankB View Post
Do the covers still fit?
The 22 1/2" WSM cover fits very tight. The 18 1/2" cover ain't even close to fitting.
I got a couple of these covers on Amazon, "Brinkmann Dome Smoker Cover". It easily fits on the big WSM. Though the 22 1/2" Weber cover fits the 18 1/2" WSM, I got 2 Brinkmann covers, just so they match.
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Last edited by BobM; 03-02-2013 at 11:41 PM..
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Unread 03-03-2013, 06:23 AM   #12
Gasket
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Nice! Would you consider making more and selling them? I sure could use a couple pairs and I have no metal skills what so ever.
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Unread 03-03-2013, 06:55 AM   #13
PaPaQ
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Looks like a factory job!
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Unread 03-03-2013, 08:12 AM   #14
bluetang
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Killer mod!
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Unread 03-03-2013, 08:35 AM   #15
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Nice work!
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