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You can easily fabricate your own charcoal basket out of expanded metal.

Try putting a bed of hot coals directly on top of the sweepers. That should soften things up.

I also love the fact that it raises the grill a few inches higher.

....because even brand new parts can get gunked up and stuck after just a few cooks?... :)

Nice. I've done something similar, except I used a 14" Lodge CI pizza pan, raised as high as possible.

My ash sweeper fins get gunked up from time to time and will stick. All I do is scrape them off carefully and they're good to go.

Awesome off-road kettle! I like it.

^^^^ Yeah, I also love that silicone handle idea!

^^^ I agree. A wider handle would be a lot easier to squeeze.

I would also change out the lid thermometer but I don't like where it's mounted. I'm currently using a Tel Tru thermometer which clips onto one of the vent holes.

As I mentioned earlier I have no trouble removing the ash catcher but I can definitely see my wife having trouble with it. But since she doesn't BBQ it doesn't matter.

OK, I'm a bit confused now that I've looked at my new ash catcher with the squeeze handle on my OTG. Are we talking about the protruding rods on each side of the catcher (10 & 2 O'Clock positions) that hook onto the housing? If so, I can't see how shortening them would make any bit of...

Hmmm.....interesting. I'm ok with it now and it doesn't annoy me but if it really improves the action maybe I'll take my dremel tool or angle grinder to the ends this weekend ...

I actually prefer the new design. My old OTG ash catcher has been fiddly the last few years so this new design was a welcomed change for me. I didn't read the instructions so it took me a couple of minutes to figure out the new latch and release system. No complaints here.

Speaking of grilling several dozen burgers I once grilled up a case worth of frozen patties from Sam's Club for my grand kid's birthday party. They weren't worth it. These thin patties produced a lot more grease and actually took longer to cook from frozen (as recommended). And taste...

I don't think I can manage that many patties at once with the likely flare ups and all....

I think I've done almost as many but with just one chimney load of coals on one side of the kettle, and like only 6 patties at a time.

Awesome!! I haven't looked at my BBQ Bible for several years but I think I need to start doing things a little differently again.... :)

I only foil when I baste with something sugary that can get caked on the moving parts of the kettle. Otherwise, I welcome all that gunk build up. :)

$99 at Home Depot. They had a stack of the copper OTG's marked down. Guess it wasn't a very popular color...??