I recently acquired a new to me grill that has a charcoal side and a gas side. I cleaned it up and replaced the regulator off Amazon and it appears to work fine.
Regulator: https://www.amazon.com/dp/B078K8DSXC...roduct_details

I decided that I'd clean up my current grill and sell it or give it to a friend. When I pulled the drip pan, it crumbled apart in my hands. I started poking around all the metal that holds the flame deflectors or whatever they are called have all completely rusted out. While the grill still works, I couldn't consciously unload this grill onto anyone else.

Here is the "new" double grill.


And here is the current grill, as you can see, it has the very desirable side burner. We've never once used the side burner, but I thought to myself, "why not just put it on the "new" grill and build a super grill?!" So that's what I did.


The current grill breaks down pretty nice. I've got a big cast iron sink I am thinking of using on another project and knew I'd need to build a stand. This grill stand is about the perfect size, so I can just use this instead.


I've been thinking for a while that I'd like to find an old grill someone is offering up for free and use it as a grinding station just to keep the mess down in my garage. Looking at the top of this grill, I got pretty excited to try it out and did a lot of the cutting and grinding in this to try it out. Turns out that it captures sparks very well. So well that it just throws them right back at you. As this grill is pretty big to just have around for when I want to grind something, I think I"ll just build a collapsible shroud out of sheet metal later. Probably something that folds up flat and I can hang on the ceiling above my workbench. Either way, I thought it was pretty nice that this grill breaks down so easy. Would be pretty nice for tailgating. I ended up breaking this top portion down and saving the stainless shell for something later. My buddy is building a stainless exhaust right now, so I let him know if he wants to make a heat shield with this, he's welcome to do so.


Onto the good stuff. I took a minute to compare the method of attachment of the "new" grill shelf, and the current grill. They are different, but nothing overly complicated in either case.
"New" shelf style


Current shelf style (held up to "new" grill).


In the end, I pulled the burner assembly out of the current grill and used it as a template to cut the existing shelf on the "new" grill.



The front plate was way too long and I needed to center up the control so it'd fit back into the burner. I cut the plate, then just lap welded the to pieces back together. All of this stuff would be perfectly fine just being tacked in, but I went overboard and fully stitched every piece that I could. I even took the time to see how well I could make the welds disappear with the grinder. Not bad, considering this is a lap joint and not a butt joint. You can see where I ground so thin I ran out of metal though.