Fabricate lid handle for Weber grill.

[9mmfan]

I have an older Weber 22.5" kettle charcoal grill that needs a new lid handle. Spot welds that hold the mounts on gave up the ghost, so a simple replacement handle isn't going to work.

This happened while the grill was on extended loan to a relative who never ended up using it, lest anyone gets the idea I don't take care of things.

Anyway, there are two holes where the spot welds used to be, and I'm thinking I can clean up the bit of rust, drill the holes a skosh bigger if need be, and get a couple stainless eye bolts, four nuts, and some washers. I can hit the whole contraption with some high-temp spray paint so it doesn't look too crappy.

My question is what to use to span twixt the bolts to form the handle. Thought of chain, but am concerned it would get too hot. Maybe a hardwood dowel with more washers and screws?

Hoping some here might have some ideas or inspiration.

I know a new grill is only $99 but other than this it's in pretty good shape, and it's a shame to just toss this one.

Thanks.

[jayinsat]

I'm thinking something like on this site: http://www.kck.com/bbq_pit_spring_handl ... stove.html" onclick="window.open(this.href);return false;

[9mmfan]

Thanks for the link, I like that. I wonder if'n there's anywhere in Weatherford (doubtful) or Fort Worth might stock something like those. We have a stove shop (wood burning, also antiques and some other random bits) a couple miles away. Maybe I'll stop in there.

[RoyGBiv]

Thanks for the link, I like that. I wonder if'n there's anywhere in Weatherford (doubtful) or Fort Worth might stock something like those. We have a stove shop (wood burning, also antiques and some other random bits) a couple miles away. Maybe I'll stop in there.

Check at a local place that sells higher-end grills. BBQ's galore or some place similar.
or a place that fabricates fire pits might have one they would use as a top handle for a cover.

[WildBill]

I'm thinking something like on this site: http://www.kck.com/bbq_pit_spring_handl ... stove.html" onclick="window.open(this.href);return false;

Using the 5" handle you can drill new holes.

[ScooterSissy]

Thanks for the link, I like that. I wonder if'n there's anywhere in Weatherford (doubtful) or Fort Worth might stock something like those. We have a stove shop (wood burning, also antiques and some other random bits) a couple miles away. Maybe I'll stop in there.

Foreman's General Store in Colleyville often has parts like that (though I can't speak to that particular part). Might give them a call.

http://www.foremansinc.com/" onclick="window.open(this.href);return false;

[ddstuder]

$6

http://www.grillparts.com/weber/categor ... aQod8YkABg

[mojo84]

I would call Weber customer service. My 8 1/2 yr old grill lid had a section that rusted out and they replaced the entire lid. Just sent them pictures of the rust and about six days later had a brand new lid.

I've found their customer service is second to none.

CHARCOAL GRILLS WARRANTIES
One Touch Cleaning System 5 years no rust through/burn through
Bowl, Lid, and Center Ring 10 years no rust through/burn through
Plastic Components 5 years, excludes fading or discoloration
All remaining parts 2 years

CUSTOMER SERVICE LINE
1-800-446-1071
7 days a week, 7am-10pm CT
EMAIL
support@weberstephen.com

[WildBill]

I would call Weber customer service. My 8 1/2 yr old grill lid had a section that rusted out and they replaced the entire lid. Just sent them pictures of the rust and about six days later had a brand new lid.

I've found their customer service is second to none.

[E.Marquez]

I have an older Weber 22.5" kettle charcoal grill that needs a new lid handle. Spot welds that hold the mounts on gave up the ghost, so a simple replacement handle isn't going to work.

This happened while the grill was on extended loan to a relative who never ended up using it, lest anyone gets the idea I don't take care of things.

Anyway, there are two holes where the spot welds used to be, and I'm thinking I can clean up the bit of rust, drill the holes a skosh bigger if need be, and get a couple stainless eye bolts, four nuts, and some washers. I can hit the whole contraption with some high-temp spray paint so it doesn't look too crappy.

My question is what to use to span twixt the bolts to form the handle. Thought of chain, but am concerned it would get too hot. Maybe a hardwood dowel with more washers and screws?

Hoping some here might have some ideas or inspiration.

I know a new grill is only $99 but other than this it's in pretty good shape, and it's a shame to just toss this one.

Thanks.

Down and simple, smallest eye bolts that fit the holes in the cover... use a nut and washer on each side of the cover, then cut a section of wood dowel the length of space between the eye bolts. Predrill holes in the dowel and use some wood screws and a washer to fix the eye bolt to the dowel..>>OR drill the dowel end for a brass insert,,, and then use a machine screw and washer though the eye bolt end.

[WildBill]

Down and simple, smallest eye bolts that fit the holes in the cover... use a nut and washer on each side of the cover, then cut a section of wood dowel the length of space between the eye bolts. Predrill holes in the dowel and use some wood screws and a washer to fix the eye bolt to the dowel..>>OR drill the dowel end for a brass insert,,, and then use a machine screw and washer though the eye bolt end.

A very simple fix! Wait until you get some "before" pictures to send to Weber before you do this.

[The Wall]

You have any old broom sticks laying around? I like your idea of using the eye bolts. Will have to put nuts on both sides as I'm sure you know. Just a friendly reminder so you don't forget to get extra nuts and washers.

[9mmfan]

I got a working prototype together. I'll likely get a smaller diameter dowel that fits inside the eyes. This one was a short section left on the cutting station, so the fine folks at Home Depot gave it to me for free.


Thanks for all your input, it is appreciated.

Post Script: yes, I will be cleaning all that dirt off the lid...

[The Wall]

Perfect! I'd just leave it as is. That wood will look good after it's been seasons for a while. And the eye bolts will give it that rustic look.