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.
I hope it helps others making their baskets.
