I then put bolts and washers on the threaded rods and then grinded off the extra piece of threaded rod. Then I drilled (and sanded) holes to accommodate the lag bolts on top and the wheels on the bottom.
The final step for the base was a coat of stain and lacquer.
Rim to Pipe to Base: To attach the steel pipe flange to the rim I used smooth top bolts (with the widest possible heads). Simply insert the bolts into the flange while making sure the lip of the bolts make maximum contact with the lip of the rim’s center hole. It may not seem like much contact but once tightened I was able to attach the steel black pipe and pick up the rim by the pipe without any give whatsoever.
I covered the hole of the pipe with a 1″ cap which fit nicely on top (so ash wouldn’t get in). I painted it with high heat paint also.
The pipe screws into the flange of the rim on one end and the flange of the base on the other. The base flange is secured by lag bolts and washers. These I also painted.
Finishing touches: The grill is on the heavy side so I inserted wheels into holes on the underside of the base for easier movement.
I used the hole from the valve stem to attach an eye hook with a couple of nuts and added a carabiner clip so I could hold all my grilling implements (tongs, brush, spatula).
Finding appropriate sized grates was tricky but with some internet searching I found a grate that would fit low in the grill to hold the charcoal and another to fit on top to hold the food. One grate could suffice as the coals could be placed directly into the rim without any hazard (only stainless or raw steel was used as opposed to zinc or galvanized metal) but I felt that coals may fall through the outer grill holes and land on the wood below if left uncovered.
Conclusion: I am very satisfied with my grill both in looks and functionality. As someone who has not yet learned how to weld (but would like to!) it was a challenge to think of a way to make a secure metal structure but I believe I succeeded.
Also if the wheels are removed and the grill is flipped upside down it makes a pretty stylish table. :)
Thanks to AmateurHour for this great project!