Weber one touch expansion

[brodieb666]

I decided to build an extension ring for my Weber one touch to increase the capacity, and add on a rotisserie. I used 50 feet of 8 inch aluminum flashing (.009 thick) and ended up with it wrapped around in a circle eight times.
I pop riveted the end closed, but it was very flexible, so I added more rivets around the diameter hoping to stiffen it up but it didn't help much. :tsk:
I was hoping to paint the ring but am worried that with the ring bending it well crack the paint.
Has anything done something similar, or have more experience with the flexibility of high temp spray paint?
If I have to add something to stiffen the ring I'd like to do so before cutting the slots for the rotisserie.
Thnx in advance.
-b

[brodieb666]

https://lh4.googleusercontent.com/-b0Bsb3XR46I/VDPzwt-wmnI/AAAAAAAAIJA/wTvMpo8HCeA/w958-h539-no/20141007_100649.jpghttps://lh6.googleusercontent.com/-wOZh0lQNV9s/VDQCkFdPd4I/AAAAAAAAIJU/xMN7VOBKHDk/w435-h773-no/20141007_110959.jpghttps://lh5.googleusercontent.com/-FyjCjEKoOcY/VDQCtKbK1eI/AAAAAAAAIJg/wQepJPnDF-E/w435-h773-no/20141007_111013.jpg

[Wickedcajun]

Why did you use something so light??? Get a big alum pot... Much stiffer, or maybe some .125 gauge alum...

[peeps]

Maybe pop-rivet a thicker ring inside at the top and bottom that will extend into the lid/kettle, respectively to help give it some perimeter support.

[smoke ninja]

I made a chimney starter out of aluminum coil stock once. I used it once too, then it melted. Hope it works.

[brodieb666]

Why did you use something so light??? Get a big alum pot... Much stiffer, or maybe some .125 gauge alum...
Where can i find a 22.5 inch aluminum pot for a reasonable price?
I used the flashing, at it was accessible, easy, and cheap. I just didn't think it would be so flexible when doubled over (eighted over?). The completed ring is 0.072 inches thick, and i had hoped that would be enough to add stiffness.

[foam2]

Cajun bandit has some nice stainless accessories for the weber kettle. They are more expensive but well made and built to last.

[smoke ninja]

You could have used piece of a drum, much more sturdy. I've never heard of an aluminum smoker. Metal expanded an contracts when heated and cooled, I hope your pop rivets don't pop

[brodieb666]

I made a chimney starter out of aluminum coil stock once. I used it once too, then it melted. Hope it works.
There should be a huge diff in the temp that the ring sees compared to a chimney. I can't see it getting anywhere neat 1200*F.

[brodieb666]

Cajun bandit has some nice stainless accessories for the weber kettle. They are more expensive but well made and built to last.

Yeah, I've seen them, I just could't justify spending $140 on an expansion ring, just to make my kettle better at what my RF already does well.

[brodieb666]

You could have used piece of a drum, much more sturdy. I've never heard of an aluminum smoker. Metal expanded an contracts when heated and cooled, I hope your pop rivets don't pop

I've seen lots of people use drums- usually saying 'DIY Weber ring for cheap! Instructions: Get a drum, buy 3 bolts, cut the drum down and drill holes for the rack bolts.' It's the first part I have a problem with. Do you often see 55 gallon drums lying around by you?

The rivets are also aluminum, so no problem there. And they don't flex, so even if paint peels off of the rest of the ring they should still be good!

[smoke ninja]

I made this with a drum I garbage picked. The whole build is from scrap parts I had lying around.

http://i1121.photobucket.com/albums/l520/smokeninjabbq/2014-08-17%2018.39.16_zps8epp2iou.jpg (http://s1121.photobucket.com/user/smokeninjabbq/media/2014-08-17%2018.39.16_zps8epp2iou.jpg.html)

I don't think it'll melt just sharing what happened when I used coil stock to build a bbq tool.

My concern for your build would be the stability of it. Add a grate and 30 or 40 lbs of food and it may caddy whomp a bit. I work with aluminum coil daily and from my experience it is not structurally strong. Hey I hope I'm wrong.

I've seen drums for less than $50, I got mine free off the curb. I built the gimmi ( haven't used it yet) and plan on fabbing a pizza oven out of the part I cut off.

Good luck and keep us posted good or bad

[IamMadMan]

Nice mod Brodie666

[Wickedcajun]

Find a sheet metal shop by you... They'll probably make you a ring for a few beers... I know i would!

[ButtBurner]

this is my version

slice of a 55 gal drum

[brodieb666]

My concern for your build would be the stability of it. Add a grate and 30 or 40 lbs of food and it may caddy whomp a bit. I work with aluminum coil daily and from my experience it is not structurally strong. Hey I hope I'm wrong.


It doesn't seem to flex with the downward force I have tried, and I can use the eventual top rack to give it more structure by using hooks to hold it us (and the ring centered) instead of just tabs.
But it does slide off of the edge of the grill and then pull the rest of the ring down with it if the pressure isn't even: I made the ring the same diameter as the grill thinking that it would be easier to cook on like that as opposed to some rings I've seen that rest inside the grill on the grate tabs. I knew I would need something to hold it in place, and I was previously thinking of having a few (stiffer) tabs facing down off the ring over the lip of the grill, but now I think I'm going to add a continuous ring around the bottom and then bend it out to fit around the outside of the grill and hold it in place.
With the bent aluminum all around it should also give it some stability, but this is something I really didn't want to do. oh well.

[brodieb666]

The drum modded rings all look nice, and probably what I should have focused on finding to begin with. Now its a matter of stubbornness to get this to work (mostly at least).
I think I've given up on painting (unless someone chimes in and says the high temp paint is more forgiving of flex then I would believe), but I can deal with the color if necessary.
Gonna try a small cook out tomorrow to see how it works before trying to add a bent Al ring for structure and holding on the grill.