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Thread: 22.5 WSM Door Handle Fix

  1. #1
    TVWBB Pro
    Join Date
    Jun 2004
    Gloucester, VA

    22.5 WSM Door Handle Fix

    Starting with my handle with the brass grommet stripped out I drilled thru from the WSM side with a 17/64" drill (slightly a over 1/4). From the handle side I used a flat bottom 3/8" drill and counter bored 1/8" deep. I then inserted a 1/4-20 UNC Socket Head Cap Screw x 2" long. I then put it all together in the same order as my new door with a 1/4" nut & lock washer Works great!

    Remember don't cut off the key on the handle! (That's The square part on the handles WSM side) The person doing my machining did and we had to do some more machining to get the handle end square to fit the square hole in the notch.

    handle-2 by mikezzmini, on Flickr

    handle-1 by mikezzmini, on Flickr

    Last edited by Mike Zarecky; 06-05-2013 at 03:32 AM. Reason: Added pics

  2. #2
    TVWBB Hall of Fame Dwain Pannell's Avatar
    Join Date
    Jan 2012
    Huntsville AL
    Very useful mod there. Nice job.

  3. #3
    TVWBB Pro PeterZ's Avatar
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    Jul 2012
    Man, that is great! Next time my handle comes off thats what Im doing.
    Thank you for sharing.


  4. #4
    New Member John K's Avatar
    Join Date
    Apr 2013
    St. Louis, Missouri
    Very nice! I already had Weber send me a replacement as my first one broke just like yours. As I'm installing the new one I already know that the same thing is going to happen to this one. When I called Weber they instantly knew what the problem was. They didn't want me to send a picture as is customary to verify a problem. Not only did they send me a new knob but they sent a whole new door assembly. It was obvious to me that they must do this several times a day! I'm no genius by any stretch but wouldn't it be more cost effective to just fix this design flaw?
    When this one breaks I am going to use your fix. Looks great!
    Black Weber Performer Platinum / 22.5 WSM

  5. #5
    TVWBB Pro
    Join Date
    Jun 2004
    Gloucester, VA
    I sent the fix/redesign to Weber Legal & Marketing. We'll see what happens.


  6. #6
    New Member
    Join Date
    Jun 2014
    Midland, North Carolina
    Mike, my brass ring just failed and I fixed it with super glue, however, while at the Home Depot, I bought your idea of the 2 inch bolt just in case of another failure.

    This failure is so common I wonder why Cajun Bandit hasn't made a better one.

  7. #7
    TVWBB Super Fan THoey's Avatar
    Join Date
    Jan 2014
    San Antonio, TX
    When I replaced my OEM Weber Aluminum door with the Cajun Bandit SS door, I installed the original Weber handle to it. I could tell this wasn't going to last long, so I order the compression latch from Amazon. Once installed, all problems solved. Tight solid door and very secure latch.

    You should be able to search here for "WSM compression latch" to find the part number and instructions on how to install it.
    Terry - 22.5" Weber Smokey Mountain Smoker - Weber Genesis S-330 - Thermopen - Maverick ET-733 - WSM

  8. #8
    TVWBB Member RonW.'s Avatar
    Join Date
    May 2012
    New Orleans, LA
    Cheap and easy fix for the Cajun Bandit Door with Original Handle that will last, , ,
    UnYawn....Ron Walker

    Member of "Motley QUE Crew" BBQ Team
    "Go BIG or Go Home"

    Cookers: 22.5" WSM, ReFurbished Spirit 700, Super Cajun Grill and a Backwoods Competitor Smoker

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