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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
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
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