Manufacturing custom (DIY) grill grates for the BGE

Henrik

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Location: Stockholm, Sweden

Author of the book Barbecue, fire and smoke
Manufacturer of:
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Hank's Signature Steak Rub

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Big Green Egg (M)
Weber 22" kettle (lime green)
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8 noname 22" kettles (black)
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#1

Manufacturing custom (DIY) grill grates for the BGE

January 21, 2018, 06:40 AM

On a BGE I would like for the grill grates to be located lower down when searing. There are 3rd party grates you can buy, but not for my size egg (M). So, I decided to weld some. Always fun with a DIY project! This took less than 2 hours.

So I measured the largest diameter, in my case it was 32 cm (12.6"). I bought 6 meters of round bar, 6 mm (just shy of 1/4"). Inspiration comes from the Big Green Egg original grates, I like their thickness, they're easy to clean.

I started by manufacturing a wooden jig out of two boards. I glued and screwed them together. These were used to shape the 'frame'.

I mounted it in a vice and started shaping the frame by hand.

Once done I cut it to length and trimmed the ends so they would fit nicely together.

I welded the ends together and did some grinding. Quick and easy, and it looks good.

I then mounted the frame on the jig again, and did some work on it to even out the circle. I then pulled it up close to the edge, so I could continue mounting the straight bars on a flat surface.

To be continued...
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Henrik

Founding Member - Moderator Emeritus

Joined: Jul 2014

Posts: 5025

Location: Stockholm, Sweden

Author of the book Barbecue, fire and smoke
Manufacturer of:
Hank's Bonafide Beef Rub
Hank's KC Royale Pork 'n Poultry Rub
Hank's Signature Steak Rub

Grills
Big Green Egg (M)
Weber 22" kettle (lime green)
PK TX
8 noname 22" kettles (black)
"Rude Boy" - my own custom built offset smoker

Thermometers
iGrill 2
Thermapen
Fireboard

Accessories
BBQ Dragon
Slow n' Sear

All my recipes, photos and information can be found at
https://hankstruebbq.com

YouTube channel
https://www.youtube.com/c/Hankstruebbq
#2

January 21, 2018, 06:44 AM

...continued:

Now's the time to weld the first bar in place. I trimmed the ends of each bar to mount it flat on the frame.

The second bar is important, as it determines the spacing for all other bars. I eyeballed each and every one of 'em.

Here's how it looks when all bars are in place. Good enough for me.

Finally time to fabricate the 'legs' (it will be hanging upside down). I made a small cut where to bend them, then welded the 'knee'.

To be continued...
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1 comment

#2.1

Henrik commented

January 21, 2018, 08:28 AM

Editing a comment

It needs some polish too before showing the final pics. Soon...
Huskee

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#3

January 21, 2018, 12:26 PM

How cool!
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DWCowles

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Hi, my name is Darrell. I'm an OTR truck driver for over 25 years. During my off time I love doing backyard cooks. I have a 48" Lang Deluxe smoker, Rec-Tec pellet smoker,1 Weber Genesis 330, 1 Weber Performer (blue), 2 Weber kettles (1 black and 1 Copper), 1 26" Weber kettle, a WSM, 8 Maverick Redi Chek thermometers, a PartyQ, 2 SnS, Grill Grates, Cast Iron grates, 1 ThermoPop (orange) and 2 ThermoPens (pink and orange) and planning on adding more cooking accessories. Now I have an Anova sous vide, the Dragon blower and 2 Chef alarms from Thermoworks.
#4

January 21, 2018, 12:34 PM

Very impressive! Grate job!
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#4.1

Henrik commented

January 21, 2018, 02:31 PM

Editing a comment

Lol! Thanks!
Mr. Bones

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#5

January 21, 2018, 12:37 PM

Very cool fabrication, Brother!
Lookin forward to yer unveilin pics!
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RonB

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#6

January 21, 2018, 12:41 PM

I love homemade solutions - great job!
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Skip

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#7

January 21, 2018, 01:49 PM

Very Nice Henrik .
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holehogg

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#8

January 21, 2018, 01:57 PM

Excellento. DIY gives one great satisfaction.
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Oakgrovebacon

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#9

January 21, 2018, 02:31 PM

Nice job Henrik!
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Troutman

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#10

January 21, 2018, 02:46 PM

See how talented Swedes are!! Nice work. Assume that’s carbon steel, do you TIG weld? Could do it in stainless.
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1 comment

#10.1

Henrik commented

January 22, 2018, 06:16 AM

Editing a comment

Yes, carbon steel. I used a MIG, not TIG. But would love to have a TIG welder in my shop.
Steve B

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#11

January 21, 2018, 02:57 PM

You’re a maniac Henrik. But I love it. Keep up the great work my brother. 👍👍
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#11.1

Henrik commented

January 22, 2018, 06:14 AM

Editing a comment

Ha ha! Thanks buddy!
Henrik

Founding Member - Moderator Emeritus

Joined: Jul 2014

Posts: 5025

Location: Stockholm, Sweden

Author of the book Barbecue, fire and smoke
Manufacturer of:
Hank's Bonafide Beef Rub
Hank's KC Royale Pork 'n Poultry Rub
Hank's Signature Steak Rub

Grills
Big Green Egg (M)
Weber 22" kettle (lime green)
PK TX
8 noname 22" kettles (black)
"Rude Boy" - my own custom built offset smoker

Thermometers
iGrill 2
Thermapen
Fireboard

Accessories
BBQ Dragon
Slow n' Sear

All my recipes, photos and information can be found at
https://hankstruebbq.com

YouTube channel
https://www.youtube.com/c/Hankstruebbq
#12

January 22, 2018, 06:16 AM

And, as promised, the finished product. I polished it a bit more after taking the photo, so now it's all shiny 'n purdy. Until I do the first cook...
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mattcotool

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#13

January 22, 2018, 06:43 AM

Nice job!
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#14

January 22, 2018, 06:54 AM

Nice work and fun post!
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#14.1

Henrik commented

January 22, 2018, 07:11 AM

Editing a comment

Thanks!
LA Pork Butt

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#15

January 22, 2018, 08:47 AM

When doe manufacturing begin now that you have the prototype? Of course two hours of labor could make them pretty pricey.
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1 comment

#15.1

Henrik commented

January 22, 2018, 10:08 AM

Editing a comment

Well, now that the prototype is done serial fab could be a lot quicker :-)