KettlePizza Modification #2

The KettlePizza has been a big hit.  The good news - with a combination of  Kingsford charcoal and oak I have been able to get the oven temp in the high 700's and the stone at  +-600 (degrees Fahrenheit).  The pies are baked perfectly and everyone enjoys making their own wood fired pizza .  The bad news - at these temperatures the Weber hinged grate will begin to bend due to the weight of the stone and the heat of the fire.  The hinged grate is not as strong as the non-hinged  and will begin to bend at the point where the hinge attaches to the solid portion of the grate.  In order to accommodate a large heavy stone, hot fire and eliminate the bending of the grate I made the following inexpensive ($3) modification.

You will need the 2 each of the following:

• 1/4"   x 1 1/4" stainless steel hex bolts
• 1/4" lock washers
• 1/4" wing nuts 
• 1/4" standard nuts 

Step one:
Drill two 1/4" holes in the pizza oven ring 11 1/2" from the back hex lower bolt (see photo below for location).  This is the lower bolt opposite the ring opening.  Important, the holes should be at the same height as the back lower bolt from the bottom rim of the ring.   Mount the hex bolts with a standard nuts screwed to the top of the threads to the outside of the kettle oven ring and attach with a locking washer and wing nut on the inside.  Align the wing nuts horizontally.  Now place the ring into the kettle body.  The outer portion of the two hex bolts fit on the lip of the kettle.

The photo below shows the position of the two holes with the hex bolts attached and the ring placed on the kettle body.

Outside view of a mounted hex bolt

Step two:

Place the hinged grate into the kettle.  The grate will will rest on the five lower wing nuts.   The photo below shows the hinged grate mounted (upside down) on the wing nuts.  The grated is mounted upside down so you do not have to remove the grate handles and  they do not get in the way when loading additional wood into the  front oven opening.  When not using the KettlePizza the grate can be used in the regular position for grilling and the handles are available for use.

Step 3:

Fire up you KettlePizza and impress your guests.

Kettle Pizza - Modifications

I have always wanted to have a wood burning pizza oven, but the cost has always been prohibitive.   I discovered, like so many others, that an insert made by Kettle Pizza can quickly and easily convert a Weber 18" or 22.5" kettle  into a pizza oven.

I followed the Kettle Pizza recommendations and was able to make some good, not great, pies.

I have been experimenting and have made modifications to the basic design that have resulted in better pies. The improvements include reducing the volume of the oven and making it easier to add wood to the fire at any time. I found removing the hot Kettle Pizza insert to add wood to be cumbersome and potentially dangerous

Materials used:

1. Weber hinged grate ($18) at Home Depot
2. wire
3. 21 x 3/4" pizza stone ($55) at California Pizza Stones
4. aluminum foil

Step 1.
Wire both sections of a hinged grate open and to the back of the grate.

Step 2.
Place Pizza Kettle insert into the base of the Weber kettle.  Now place the wired hinged grate into the Kettle Pizza insert UPSIDE DOWN on the bottom set of standoffs.  This way the handles will not get in the way when adding wood and a larger pizza stone can be placed on the grate.

Step 3.
Place your pizza stone onto the modified grate. I use a 14 x 16" stone.  I like adding wood from the front of the kettle, but you could use a smaller stone and add wood from the sides. Just rotate the modified grate.   A good source for quality pizza stones is California Pizza Stones.

This view shows the pizza stone and grate set into the Kettle Pizza insert from the front.  I found loading from the front easy to add more charcoal or wood while cooking.

Step 4.

Insert a second regular grate UPSIDE DOWN on the top section of the Kettle Pizza insert standoffs.   This will allow you to place a 21" pizza stone above the cooking surface thus reducing the volume of the oven.   If you place the grate with the handles in the up position the largest stone you can place on the grill is 19".  This will leave a lot of space for the hot air to fill the dome of the kettle.  The Serious Eats site recommended this modification using a smaller stone with improved results.  I tried a smaller stone and have found that the larger one keeps the oven temperature more constant while acting as a refractory ceiling on top.

Step 5.
Place a 21" stone on top of the inverted grill and seal the space between the stone and the kettle with aluminum foil.  Place the lid, with the vents closed, on top.

Below is a picture showing the assembled kettle. The lid is placed on the KettlePizza, with the vents closed, when  in use.  The opening in the front, between the stone and the kettle, is used to add wood at any time. Drop the wood in and move to the back of the kettle with a fireplace poker or similar tool.  Prior to this modification I would remove the Kettle Pizza insert to add wood. Cumbersome and potentially dangerous.  Now I can continue to bake pies without having to remove the insert.  The two pictures show the KettlePizza without the lid.

And, the results!