What gauge steel is recommended for a diy kettle ring? Any thoughts on a preferred height? Stone type and thickness? Thanks!
Do you think cutting the stone into 4 pieces and arranging them in the wave pattern would be beneficial?
Bob, I've put in considerable time researching a DIY KettlePizza insert. Thin guage metal can support either the Weber lid or, if you get a large enough stone, a large stone. Flashing can be cut with tinsnips- that's what I've been recommending. If you know you're going to be sticking to NY temps (below 800), then aluminum flashing is ideal- cheap and easy to cut. As long as it's quality flashing. I've been reading reviews on Home Depot on aluminum flashing that's little more than foil- that wouldn't work. If you want to work with Neapolitan temps, then the options are not quite so elegant. Home Depot carries galvanized steel flashing, but you've got the threat of zinc poisoning. I still firmly believe, that, if you know what you're doing, you can safely burn the zinc off galvanized steel, but everyone might not be comfortable with this route. I wish I could find a cheap source for regular steel flashing, but I'm not having any luck there. Copper flashing conductivity isn't ideal, although it will work, but it's the most expensive option.
The height of the insert depends on what you're comfortable launching into and the thickness of the stone. I would say that a 3" vertical gap is ideal, but can be a bit difficult to work with.
For the hearth, on a 22.5" grill, you'll want an 18 x 1/2 or 3/4 round cordierite stone (or firebrick splits) and, for the ceiling, a 21" round cordierite stone.