Originally posted: 03/01/2001
Last updated: 03/30/2010

Preventing Lump Charcoal From Falling Through The Grate 

One of the challenges of using lump charcoal in the Weber Bullet is that sometimes the small pieces tend to fall through the charcoal grate into the bottom of the cooker. There are two ways to solve this problem.

The first approach is to place a second charcoal grate on top of the original one, turned 90 degrees so the two grates run in opposite directions. This creates a grid that prevents little bits of charcoal from falling through.

Picture 1 shows a Weber #72501 Charcoal Grate placed inside the charcoal ring—it's a perfect fit. This 13-1/2" grate, intended for use in 18-1/2" kettle grills, is readily available at hardware stores, home centers, and barbecue specialty stores.

The second approach is to place a piece of expanded metal over the original charcoal grate. The holes in the expanded metal are small enough to prevent even the smallest pieces of lump charcoal from falling through.

Picture 2 shows an example of expanded metal on the WSM charcoal grate. Expanded metal can be purchased in small sheets at hardware stores and home centers for just a few dollars. Don't buy the thickest variety available--a relatively thin gauge is sufficient and will cut easily with tin snips.

Remember that when using double grates or expanded metal, it's more difficult for ashes to fall through the grate into the charcoal bowl. If you notice that the fire seems to be dying out when it shouldn't, it may be smothering in its own ashes. Stir the coals gently, dislodging the ashes and rejuvenating the fire.

Closing The Gaps In The Charcoal Grate

A common complaint about the stock WSM charcoal grate is that a small amount of charcoal falls through the wide gaps on either side of the grate. Why are those gaps there? Who knows. To the best of my knowledge, there are no gaps on any other model of Weber charcoal grate.

I don't find this to be a problem when I use my cooker. I just accept the fact that a few coals will find their way through the gaps. If this really chaps your hide, you have a couple of options. Use either the double grate or expanded metal solution described above, or if you know someone who does welding, have two additional rods welded in place to close the gaps. This approach is shown in the photo above.

Separating Leftover Coals From Ashes

This picture shows the charcoal ring and grate from a cooker belonging to the Jim Minion and Jack Rogers of the Cardogs Barbecue Team. The two pieces have been wired together so they can be handled as a single unit. Click on the picture to view a larger image and you'll see where I've circled the points at which they have been fastened.

When the cook is over and the coals are cold, just shake this unit back and forth to dislodge the leftover ashes, leaving behind only clean, reusable charcoal!

3-in-1 Charcoal Grate Modification

Sean Flanagan from Australia created this elegant modification for the charcoal grate that 1) closes the gaps on each side of the grate, 2) adds handles for lifting the grate out of the cooker, while 3) holding the charcoal chamber in place so the ashes can be shaken out. Thus, the "3-in-1" grate modification!

Sean fabricated the bars and handles using 10mm x 3mm (about 3/8" x 1/8") mild steel flat stock and welded them in place.

"I spaced the handles so that the charcoal ring slides down over them, and I slightly leaned the handles out, so that the charcoal ring locks in place and stays firmly against the grate.

"The handles stick up above the charcoal ring 3cm (about 1-1/2") to give comfortable handles to grab onto. It works like a charm!"

Photographs of 3-in-1 charcoal grate: 2004 by Sean Flanagan.