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Looking good so far and when I first got started welding I had a guy tell me my welds look like "metallic diarrhea" it still makes me laugh to this day. Your welds look a lot better then that but the most important thing is they are strong and get the job done.
I would just wire wheel it, and rub it down with some flax seed oil and re-season it and you should be good to go. Usually once you get to using it often it builds up a nice seasoned layer that protects it from rusting.
For the grates I have been using 1x1x1/8 angle iron, and #9 flat ground expanded metal with good luck. And if you skip around when welding the 1/8" keeping the heat down as much as possible you can get away without too much warping but the key is small skip welds all over until you get it...
Looks fantastic I have a corned beef in the freezer I think it will be thawed and smoked this weekend.
Do you have a recipe for the Russian sauce that your willing to share?
That sounds like a pretty good sized basket I definitely wouldn't want to be lifting that up much either fully loaded. I am thinking a slide is in order with an anti tip plate welded in there kinda like you would a rack.
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