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View Full Version : WSM Middle Handle Mod (pr0n)


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

Dirtbuddy
03-02-2013, 09:29 PM
Nice work Bob!

HeSmellsLikeSmoke
03-02-2013, 09:33 PM
They sure do look official.

Hoss
03-02-2013, 09:35 PM
Sweet mod! :clap2:

Big M1ke
03-02-2013, 09:37 PM
I likey :thumb:

nucornhusker
03-02-2013, 09:39 PM
They look great. I've always wondered why they weren't on there already.

Bluesman
03-02-2013, 09:39 PM
First class job, nice attention to detail............:clap2::clap2::clap2:

Bob13
03-02-2013, 10:02 PM
Looks spot on... great job!

HankB
03-02-2013, 10:09 PM
Thanks for posting the info.

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

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

Thanks.

BobM
03-02-2013, 11:09 PM
Thanks for posting the info.You are quite welcome, I hope it was helpful!


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.


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.


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. :grin:

Gasket
03-03-2013, 06:23 AM
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. :icon_smil

PaPaQ
03-03-2013, 06:55 AM
Looks like a factory job!

bluetang
03-03-2013, 08:12 AM
Killer mod!:clap:

charrederhead
03-03-2013, 08:35 AM
Nice work! :thumb:

BobM
03-03-2013, 10:29 AM
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. :icon_smilI don't have the time. :sad: