I tested out a cheap wood basket over the weekend to see if it offered any performance improvement over my existing setup. I had been overlapping 2 fire grates to keep coals from falling through or falling over the edge (the Yoder heavy duty wood grate isn't wide enough to extend to the edges), but I still struggled a bit with preventing the coals from spreading out too much. Considering how much time is involved in creating those coals from actual log burning (not the Yoder way using 2 chimneys full of lump, and then another chimney for every 3rd log), I want to keep them concentrated enough to form the "coal base" needed to ignite new wood.
I found a light-weight basket that matched my size requirement for about $65 bucks online. It's 12x12x6, but made from heavy sheet metal that has been laser cut. It feels light and cheap, but at least it doesn't hurt my back when I pick it up.
The basket is the same width as the Yoder charcoal basket, but it's square, so it can slide back and forth. Notice the dark smoke line on the inside of my modified door. Now that the upper vent is blocked, the smoke line dropped down almost to the mounting bolt in the center.
I did my first cook without using a grate to support the basket, but after seeing how much warpage the basket bottom had after cooking 1 brisket I decided I'd start using the factory grate to support it from now on.
The basket seen through the SE vent opening. Note: This photo was taken on Saturday, and I have been cooking on my modified Wichita every weekend since the door mod, and still no scorch marks.
This is probably the best view I have right now of the black high-temp silicone bead I added to seal up my fire door when it's closed:
I did a reverse-seared tri-tip on Sunday night, and needed to use the grill grate, so it was important that the basket height not interfere with the grill grate. The factory grate was just a tad too wide for the basket to fit, so I removed 1 rib from the grate to lower it down enough.
The removed rib:
Ready for my second cook test, after placing the basket on top of the narrowed factory grate. It's just about the right size for the small splits I've been working with. I'm thinking I might try moving it all the way to the rear for the next brisket cook to see if it works better back there.
Warpage on the bottom of the basket after the first cook:
There is visible distortion in this shot if you look at the bottom section of the basket. My guess is this basket wouldn't stand up to heavy usage for very long, but if only the bottom blows out maybe a new piece could be cut to overlay the flanges to prolong its life. The sides didn't warp at all.
Impressions
The basket did a good job of containing the coals, no doubt. I was able to get a good pile of coals going without having to worry about them rolling off to the sides or through the grate.
I found that the basket was wide enough that my fire tended to pile up against one side, so I still had to make sure the wood didn't roll off the pile, and if it did it was a little more difficult to pick it up with my usual fireplace tongs because of the confined space within the basket.
I do actually think my coal bed was more stable and fresh logs ignited more quickly with the basket. I definitely had a bigger coal base when it came time to sear my tri-tip over the fire. That's one area I struggled with before when I cooked steaks on the Wichita. The last time I tried it I had to get out the charcoal chimney because I could not build up a big enough bed of coals with oak on the factory fire grate.
I'm going to keep using the basket for now to see if it grows on me.