The first pic shows one of the two 30" pieces being shaped in my jig pipe.

Once these are formed I lay two 22" Weber charcoal baskets 90° to each other and tack them together.

When this is done I weld the first section of expanded metal to the grate and mark where to trim the excess for a 180° fit.

Then I weld up the second piece trim off its excess and weld up the seams.


Next I measure the circumference to see how much 1" x 1/8" flat bar will be needed to strap the top.

With this measurement I preform the flat bar in my pipe jig.

Then with a few clamps I weld the strap on.

After the strap I fit and weld in the vertical pieces over the expanded metal seams.

Then I build the lugs for the hanger.

Then I weld them on 180° to each other.

Now that the basket is complete I move onto the handle.
First I lay out the handle diagram on my table then I fit a chipping hammer spring on some 3/8" rod and bend it into a squared U shape and tack it down where I want it.

Then I heat and bend the handle out to the first intersecting line and tack it down.

I then follow up with the final angle and tack it down then I add a 1/2" rod as a jig for the roll hook.

Here is it with it cut loose ready for clean up.


Then I add three 3" tall legs.

And the finished product.

