On the two we're building right now, we made grates out of 7/8" square bar stock, then welded in a couple more pieces of the bar stock to the side of the ash bin as guides. You can't tell from this picture, but the grates extend just past where the opening ends, then the two side rails that the cross pieces are welded to extend a little farther. The last cross piece (closest to the door) is actually a piece of 3/4" angle. It's turned down to form a lip you can reach in and grab with your fingers to slide the grate out.
We're building the smokers at my friend's house. I won't be back there for a couple of days, but can get him to send me more detailed pics if you need them.
Exactly how I built mine except I used rebar for the cross pieces. Works well and gives you the ability to dump the charcoal chute if you get a flame-up in it. Just drag out the grid and let it all dump into the ash pan.
Learning generally boils down to "Repetition or the avoidance of pain", some people learn by doing, some by watching and some just have to pee on the electric fence.
Whether you think that you can, or that you can't, you are usually right. Henry Ford
Another cracking thread. I was only thinking about how to do this a couple of nights ago. I love the way everyone on here is so helpful, sharing and encouraging others.
What size gaps do you guys recommend to have small pieces fall through onto wood chunks? I also made an extra large ash box that will fit full size logs. Because why not.