thsmormonsmokes
Smoking Fanatic
A no-weld expanded metal basket is pretty easy.  Some people bend theirs into shape.  I tried that but my expanded metal was too heavy of a gauge to do that very well.  4 hours later and a destroyed pair of gloves and a little blood donated to the cause, and I had a "basket" that probably wouldn't have held much charcoal even if I could have fit it into my firebox.  
So all I did was measure the dimensions, then cut 5 square pieces of expanded metal, one for each side of my basket. Then I used tie wire to hold it together and assembled it in my firebox. You have to be careful to wind the tie wire tight and keep twisted part facing up or it can hang up the ash pan when you try to remove it to dump ashes on a long smoke. Other than that minor issue, this was a much more simple way then bending it into shape, or welding one (which I also tried unsuccessfully). Here's what my final product looks like:
	
		
			
		
		
	
				
			So all I did was measure the dimensions, then cut 5 square pieces of expanded metal, one for each side of my basket. Then I used tie wire to hold it together and assembled it in my firebox. You have to be careful to wind the tie wire tight and keep twisted part facing up or it can hang up the ash pan when you try to remove it to dump ashes on a long smoke. Other than that minor issue, this was a much more simple way then bending it into shape, or welding one (which I also tried unsuccessfully). Here's what my final product looks like:
 
				
		 
										 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		 
 
		
