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  • UDS Charcoal Basket -- No Welding Required

    Finally got around to building another charcoal basket for the UDS today. I already have one (13.5" x 8") but decided to build another. This one will be 17" x 6". It will hold a little more fuel for longer cooks with the deflector.

    Decided to document it as it's pretty easy to do and a very nice alternative for those of us who can't weld.

    Here's what I used.



    A charcoal grate from a Weber kettle (This one was 17" but another popular size is 13.5")
    A piece of 3/4" #9 ,expanded metal (55" x 6" if using a 17" grate, 44" x 8" if using a 13.5" grate)
    A piece of 1/4" diameter rod for the handle
    Three 3-1/2" x 1/2" bolts
    Six 1/2" nuts
    Six 1/2" flat washers
    Three 1/2" lock washers
    Some wire

    As I said, no welding required.

    Here are all the tools that you need.



    Gloves, pliers, wire cutters, some wrenches . . .

    And to assist in bending . . .



    A propane tank.

    Oh, and a couple of C clamps and a vise will come in handy too.

    Now let's get to building it.

    First thread one of the nuts as far as it will go onto one of the bolts.



    Put a flat washer on, then the grate, then another flat washer, the lock washer, and finally another nut.



    Tighten the nuts with the wrenches and you have a leg that will hold the grate about 3" off the bottom of the drum.



    Repeat with the other two bolts and you're good to go.

    Next, lay the expanded metal on the ground, lay the propane tank on top of it and while standing on one end of the expanded metal, pull up on the other end to bend it around the tank.



    Keep working with it until you get it into a semi round shape.



    Bend it to overlap at one of the diamonds and clamp the ends together.



    The first time I did this, I was able to do it by myself. Today, though, I had my son help me. It's MUCH easier with a second pair of hands.

    Now cut some small pieces of wire and put them through the diamonds and twist to lock into place.



    After you do this in a few spots, you can take the clamps off and put a few more in for good measure.



    Then set the round basket part on top of the grate and use wire to tie the sides to the grate in as many places as it takes to make you feel comfortable that the bottom won't come apart from the sides. Just loop the wire through the bottom row of diamonds and around the edge of the grate and twist.



    I didn't get any progress pics of that unfortunately but it's pretty straight forward.

    Next use a vise or something similar to bend hooks in the end of the 1/4" rod.



    Of course you could just use wire if you wanted to, but I figure the rod will last longer since it will spend much of it's life just a few inches above a hot coal bed.

    Hook the handle into the sides of the charcoal basket and you're done.



    I should have gotten a little bit longer rod I suppose, but anyway now they're done.



    Hope this gives some of you planning UDS builds some helpful ideas as to how to construct your charcoal basket.

    Dave
    CUHS Metal Shop Reverse Flow
    UDS 1.0
    Afterburner
    Weber Performer
    Blue Thermapen
    Thermoworks Smoke with Gateway
    Thermoworks Chef Alarm
    Auber Smoker Controller
    Proud Smoked-Meat Member #88
    -
    "All welcome, take what ya need, share what ya know. " -- Richtee, 12/2/2010

  • #2
    Thanks that is great info!

    Comment


    • #3
      Looks about like what I did. What do you use for an ash pan in yours?
      Propane Smoke Shack
      UDS
      Great Outdoors Smoky Mountain
      sigpic

      Comment


      • #4
        Originally posted by rbranstner View Post
        What do you use for an ash pan in yours?
        Cheapo table top grill.



        I think it was like $8 at my local ACE hardware store. Threw everything in the trash but the charcoal pan.

        Drilled some holes in it that line up with the intakes on the drum. Added bolts to keep it somewhat centered in the drum so that it can't slide over and block an intake. Had that happen once as a result of overenthusiastic shaking of the drum to knock the ash loose.

        I found a link and I think this is the same model. Sounds about the right size.

        http://www.acehardware.com/product/i...LAID=109385178

        Dave
        CUHS Metal Shop Reverse Flow
        UDS 1.0
        Afterburner
        Weber Performer
        Blue Thermapen
        Thermoworks Smoke with Gateway
        Thermoworks Chef Alarm
        Auber Smoker Controller
        Proud Smoked-Meat Member #88
        -
        "All welcome, take what ya need, share what ya know. " -- Richtee, 12/2/2010

        Comment


        • #5
          Hey Dave, I found that the wire bail off a 5 gallon bucket makes a perfect handle. Plastic grip removed of course.


          Comment


          • #6
            Originally posted by MichChef View Post
            Hey Dave, I found that the wire bail off a 5 gallon bucket makes a perfect handle.
            That's a darn good idea.

            Dave
            CUHS Metal Shop Reverse Flow
            UDS 1.0
            Afterburner
            Weber Performer
            Blue Thermapen
            Thermoworks Smoke with Gateway
            Thermoworks Chef Alarm
            Auber Smoker Controller
            Proud Smoked-Meat Member #88
            -
            "All welcome, take what ya need, share what ya know. " -- Richtee, 12/2/2010

            Comment


            • #7
              Stainless steel zip ties found in the electrical department of your home store work great connecting the expanded metal to the grate.
              WSM and UDS - iBQ'n BBQ Team co-founder TheBBQSuperstore.com

              Comment


              • #8
                Farmer Engineering at it's finest!!


                Todd
                - http://www.AMAZENPRODUCTS.COM
                - 40" MES
                - Char-Broil The Big Easy Infrared Turkey Fryer
                - Stainless Steel BBQ Grill
                - Gander #12 Grinder
                - Cabelas 20# Stuffer
                - Gander Meat Mixer

                Comment


                • #9
                  Nice Job thats the same way I did mine I used Mechanics wire on mine tho yours looks better


                  Happyness is a full smoker

                  Comment


                  • #10
                    WOW, does that look like a great basket.

                    Nice tutorial.

                    Comment


                    • #11
                      Looks good, I like the idea of it being wider than taller, seems like it would spread the heat the full width of the drum better.

                      Comment


                      • #12
                        Nice work, looks great.
                        http://www.cadischmda.com/meshtec-expanded-metal.asp

                        Comment


                        • #13
                          I love this basket, this is guide I'm using to build my new basket! Awesome Job!
                          Mike Reid
                          22.5 Weber
                          Smokenator
                          Future home of a UDS

                          Comment


                          • #14
                            How long can you cook with a full basket of lump on the large basket at about 250 degrees? Can you get 12 hours or more?

                            Comment


                            • #15
                              Originally posted by jazz586 View Post
                              How long can you cook with a full basket of lump on the large basket at about 250 degrees? Can you get 12 hours or more?
                              With no deflector and mild outside temps, 12 hours is not a problem with the small one. Don't know that I've ever run out with the big one even on a brisket cook going between 230° and low 240s. Usually 16 hours or so.

                              Dave
                              CUHS Metal Shop Reverse Flow
                              UDS 1.0
                              Afterburner
                              Weber Performer
                              Blue Thermapen
                              Thermoworks Smoke with Gateway
                              Thermoworks Chef Alarm
                              Auber Smoker Controller
                              Proud Smoked-Meat Member #88
                              -
                              "All welcome, take what ya need, share what ya know. " -- Richtee, 12/2/2010

                              Comment

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