Great tutorial and plans! I just started a rebuild on a New Braunfels Hondo and will definitely add this to my list.
Will post pics thru the process.
I just finished building this basket and it was a cinch. Not sure how long it took me in minutes but I was done in three Corona time (TCT). I am adding a couple pics to show the improvisation used to construct the basket.
My grill, Oklahoma Joe "Highland", came with a coal grate for the smoke box. I used it as the straight edge to bend the metal as I didn't have any sturdy material handy; such as a 2X4.
After bending 3 of the four sides using the grate, I stood inside of the basket (size 10.5 house shoes, to bend the fourth side).
After the final bend my basket looked like this.
I bent the tabs in according to eaglewing's instruction and ended up with this magnificent basket.
I was just going to suggest that. If you live near a few fellow smokers, a 4x8 sheet is much more reasonable to go in on $$$ wise than the smaller cuts. Any good metal yard has or can get SS expanded. There is a few online sellers that will cut it to your specs as well.
Thanks. just made one of these for my new Char Broil offset smoker. It was a gift for fathers day so I'm not complaining.
Anyway, I went with your measurements and made a cardboard mock up. It fit fine. When bending the expanding metal, I was a tiny bit wide. So, i had to put some clamps on it and kinda manipulate it. Still looks decent but it a small amount bowl shaped. Will use of this in the smoker cause it to expand? If so, it'll be tight getting it out.
Also, do most folks use these on top of the charcoal grate or do you remove the grate?
Great Tutorial!!! I will say, you learn a ton just building one of these...The next one is for the Smoker, so it will look a bit more polished!
Going to give the old grill a bit more life by ripping out the guts and adding this basket!