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The dimention between the rf plate and the main cooking grate is dictated by your circle segment height.
ie, I have a dia of 20", my rf plate was set at 4.5".
I wanted my grates to be flush with my door cut out, so the math did its self for me and it worked out to 5.5" above rf plate which...
I made two grates roughly about 19.5x19.5 with 1x1" tubing, and they support any food I would ever put on my smoker. It's a strong mesh.
FB looks great by the way.
Long way of diamond pattern is 2"
Short way is 1"
.125" thick.
I've used this before lots and it seems to hold up. Great for smaller appatisers as well as nothing falls through.
I will send a pic and the dimensions of the mesh I used in a bit. It's a tight pattern and fairly thick. 3/4 #9 if I'm not mistaken.
I did built a basket, which I load up with charcoal and then add wood to that.