I'll chime in here. I have recently done a lot of steel fabrication work including some with expanded metal. You can buy expanded metal anywhere that sells steel. The easiest place to buy steel is Everett Steel, who has plants in Everett, Seattle and Woodinville. Their prices aren't real great, though.
There is a place called Grating Pacific in Tukwila that has a big shear out back. Anyplace that has a shear has a drop box. You may be able to get some action if you go around back and ask the guy on the shear if you can pick through their drop box. Remember to bring gloves. Anyway, you can buy a 4x8' sheet and have it sheared the way you want it, and just bring home pieces.
A manual bench shear does a good job on 3/4-9 expanded steel. I have a post-mounted Whitney shear with which I can whiz through the stuff. I like to trim off all the little stubbies from all sides and only work with nice clean edges.
A small slip roll will really help in making round charcoal baskets. Here's the cheapest one:
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=36698
Expanded steel is very easy to cut with a plasma cutter as long as the plasma cutter has an interrupted cut function. It is also very easy to weld with a MIG welder loaded with smallish wire like .030".
Anyway, a big thanks to JD for my first two food-grade drums! I found out that the way the pros remove the tan antirust liner is by burning followed with blasting with fine steel shot. I have a connect down at Industrial Container Services down by the Duwamish River, the place by the south end of the 1st Avenue South Bridge in South Seattle with bazillions of drums stacked up. He told me about their method of cleaning off the liner. It may be possible for BBQers to buy drums from them in small quantity, don't know yet. I have bought drums in the past from a place on Airport Way, although I don't know if they're still in business.
I should be up and running on my first UDS very soon.
seattlepitboss
