Prices for ceramic cookers have dropped a bit this summer. If you're in the market for one, shop around and find the right one. The one thing you need to consider is where to prop it up. Many brands don't offer every accessory, hence you'll need to buy (bad move) or build your own table.
Step 1: Gather Materials
Counter sink bit
Phillips head bit
1 box 2 inch screws
1 box 1.5 inch screws
Wood plugs (flat top)
80 grit sand paper (get plenty)
16 x 16 slate tile
2x4's - 68 ft (grab extra in case of mess ups)
1x4's - 94 ft (grab extra in case of mess ups)
I salvaged every piece of wood, to include the saw horses. I live in a neighborhood that is still being developed and had the opportunity to visit each build site and pick through scraps. Be carefull if you do this. Some builders have a no salvage policy, so speak with the foreman at each site and get his/her permission. This step will help defray the cost and make this option fiscally viable. If you can't salvage enough, then you might want to buy one.
Step 2: Make Plans
Also pay attention to your own plans. It's easy to get in the groove of sawing and fastening without really paying attention to what you're doing. I made the mistake of turning the 2x4's ninety degrees.
Step 3: Cut and Fasten
ALWAYS measure twice and cut once!
Step 4: Don't Forget to Countersink!
Ensure the bit you choose is smaller than the screws you will use to drill and fasten each board.
Step 5: Make the Middle Shelf
Once again, I didn't pay attention to my own plans and bought a piece of tile that was too small (I originally provisioned for an 18x18 in). I placed the 16x16 in slate tile down to ensure it would have enough room and measured around it. You'll also need to make sure it's completely level. I'm not ashamed to say I had to use some wood glue and a couple of shims. Even though your BGE has a lifetime warranty, you don't want to endanger that bad boy.
Once you are finished with the bottom, then begin on the middle shelf. Don't forget those countersinks! Also use those quick clamps, a level, and refer often to the plans you made.
Note: I left the top shelf off on this instructable. I'm doing another instructable for this one, so be sure to tune in for it. Unless you want it to turn out exactly like mine, just add those 1x4's for the top row in the same manner you added them on the others.
Step 6: Hammer in Wood Plugs
This picture is the plugs after they've been stained and finished.
Step 7: Insert One Hole
First, find the center of of the slate tile on the bottom shelf. Then measure at a right angle to the side edge and back edge. Use these measurements to find where that location would directly be on the shelf above. Mark this point with a pencil. This is now the center point of the hole you will cut out.
Next, cut a slim piece of cardboard a few inches longer than the radius, approximately 13". Take a tack or nail, and pin one end of it to the center point you just marked with a pencil. Make sure it spins in a complete circle.
Next, measure from where you nailed or tacked the cardboard end exactly 11". At the end of where you measured 11", stick the tip of your pencil through so you can mark a circle as you spin this cardboard in a complete circle.
Next, check your work and make sure your diameter is 22" and not lopsided.
Last, grab the jig saw and cut along the line you just made. With gaps between each board, you shouldn't have to drill starter holes.
Step 8: Finishing, But Not Finished
Then take a medium grit sand paper for your sander. Lightly sand. The objective here is to remove burrs and smooth out the surfaces. Don't undo everything you just did distressing. Take a moist rag and clear away the saw dust.
Next grab a rag and start staining. Pick your favorite shade and make smooth strokes so the color isn't blotchy. Make sure to get it between large gaps in the boards. Wait until dry before sealing.
I suggest choosing a sealant that isn't glossy. Before you start painting on the sealer, make a few bowls by folding aluminum foil. Make sure these are wide enough to place beneath each foot. You'll use these as a dam to seal up the bottom of each leg. Pour some sealer in each bowl so it can begin to dry. Use a good brush to paint on the sealer and use smooth strokes.
Step 9: Bells and Whistles
Your BGE is likely to weigh quite a bit. Take each piece and place it in separately. Always lift with your legs!