BobM
03-02-2013, 09:02 PM
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.
http://imageshack.us/a/img33/4370/wsmhandle02.jpg
I replicated the prototype bend on the next two pieces of flat stock.
http://imageshack.us/a/img13/5391/wsmhandle04.jpg
Cut up, drilled and sanded, including the prototype.
http://imageshack.us/a/img515/3148/wsmhandle08.jpg
Painted black.
http://imageshack.us/a/img543/8632/wsmhandle10.jpg
To match my 22 1/2" WSM, I got 2 dark gray handles from Weber.
http://imageshack.us/a/img17/9417/wsmhandle22.jpg
To match my 18 1/2" WSM, I got 2 light gray handles online.
http://imageshack.us/a/img138/4877/wsmhandle09.jpg
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.
http://imageshack.us/a/img42/5559/wsmhandle07.jpg
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.
http://imageshack.us/a/img692/5359/wsmhandle20.jpg
The 18 1/2" WSM
http://imageshack.us/a/img836/6135/wsmhandle13.jpg
The 18 1/2" WSM, closeup
http://imageshack.us/a/img685/5861/wsmhandle15.jpg
The 22 1/2" WSM.
http://imageshack.us/a/img339/8213/wsmhandle16.jpg
The 22 1/2" WSM, closeup.
http://imageshack.us/a/img820/1739/wsmhandle14.jpg
The 22 1/2" WSM, showing my other mods.
http://imageshack.us/a/img805/6647/wsmhandle17.jpg
The pair.
http://imageshack.us/a/img839/9348/wsmhandle11.jpg
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.
http://imageshack.us/a/img33/4370/wsmhandle02.jpg
I replicated the prototype bend on the next two pieces of flat stock.
http://imageshack.us/a/img13/5391/wsmhandle04.jpg
Cut up, drilled and sanded, including the prototype.
http://imageshack.us/a/img515/3148/wsmhandle08.jpg
Painted black.
http://imageshack.us/a/img543/8632/wsmhandle10.jpg
To match my 22 1/2" WSM, I got 2 dark gray handles from Weber.
http://imageshack.us/a/img17/9417/wsmhandle22.jpg
To match my 18 1/2" WSM, I got 2 light gray handles online.
http://imageshack.us/a/img138/4877/wsmhandle09.jpg
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.
http://imageshack.us/a/img42/5559/wsmhandle07.jpg
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.
http://imageshack.us/a/img692/5359/wsmhandle20.jpg
The 18 1/2" WSM
http://imageshack.us/a/img836/6135/wsmhandle13.jpg
The 18 1/2" WSM, closeup
http://imageshack.us/a/img685/5861/wsmhandle15.jpg
The 22 1/2" WSM.
http://imageshack.us/a/img339/8213/wsmhandle16.jpg
The 22 1/2" WSM, closeup.
http://imageshack.us/a/img820/1739/wsmhandle14.jpg
The 22 1/2" WSM, showing my other mods.
http://imageshack.us/a/img805/6647/wsmhandle17.jpg
The pair.
http://imageshack.us/a/img839/9348/wsmhandle11.jpg