convert old bar-b-kettle (26) to OTG

[TroyRedington]

i'm really falling in love with the real estate on this 26" grill.

but I'm not enjoying the 3-daisy wheel vents on the bottom

They're hot to touch. Hard to turn (under surface was rusty and had to be completely repainted)

And I REALLY dislike little falling embers. I do my cooking on a wooden patio. I nearly burnt down my parents house as a kid with falling embers from my dads grill. I'd really like to put a one touch gold sweeper and ash pan on it.

The challenges.
- cover the holes without making exterior look bad
- cover holes without ruining the surface for the one-touch cleaning system

I'm not concerned about the hole required for the cleaning system, there's already a dimple at the very bottom. I'm also not concerned about mounting the ring and ash pan.

I'm a little torn about modifying (drastically) such a rare and nostalgic grill - but in reality, this beast will likely be my primary cooker.

 

[Jim Lampe]

Troy, i have (had) the same concerns.
However, I beleive trying to modify the great old kettle to make my life easier... is a mistake.
So.
I will buy a NEW 26" Weber next spring and use the old 26" kettle for special events.

...and I suggest you do the same.

 

[Shaun R]

Here's my take. I only use one front vent for cooking and I don't lose any ash at all. I find more than enough air comes through one vent. Besides it isn't air tight anyways. I just dump the ash out every two weeks or so. However, after saying that the new 26 is a pleasure to cook on. It's very roomy, it has the sweeper, and the main grate is SS and sets higher than the oldie does. It even has the lid holder ash catcher and thermometer. If I could only have one kettle that would be it. The old ones are a kick to cook on though. I take it you are finished with the project now? I would love to see some pictures of it in action Troy. Please post a few. It's like watching a throwback game.

 

[AJ S.]

Troy,
I agree with everyone else.
It would be a shame to modify it.

If you want a workhorse daily cooker, I recomend that you save up and buy a new 26er.
If thats not desirable I think that you would do better to try and control the ash collection in a different way.
A big pan under the grill. Something to prevent a deck fire. I trust you have the weber ash pan? Like Shaun said, close off 2 of the vents and use the third for air and temp control. It should ba ll you need for most cooks.
You could also try and fabricate or find a pan that could go inside the bottom of the bowl, to collect the ash, yet still let air flow. Similiar to the type that was used on the Sears grills. I will see if I can get you some pics to look at.
AJ

 

[TroyRedington]

i feel the same way as you guys, really.
there's a voice in the back of my head telling me not to do it.

i am using the original ash catcher, in addition to 3 charcoal grates (until i can get some expanded metal)

an actual ash pan on the inside is a great idea though!

 

[Kaz S]

I say go for it. Make it a badass daily custom old skool cooker.

Leave the 3 daisy wheels for when u need more airflow. You cook tuna at 1000• Don't you? and install the sweeper arms. The sweepers on the inside and daisy's on the outside. Leave the daisy's closed most cooks and leave the disc underneath the gold assembly then when you open the daisy's you can remove the ash pan and catch the ashes old skool.

 

[Brian Moriarty]

I feel the same way about mine, but have also gotten used to just using one vent.
All my cooks so far have been indirect and I modified the charcoal rails with a 3.5" x 15" strip of expanded metal and the added space leaves enough charcoal to cook a couple meals.
I ordered a replacement ash catcher and it is the same size as the 22" kettle, which is a disappointment, so I'm thinking of using a pizza pan in its place.