UDS too large for Weber kettle dome

I had the same problem. However, instead of cutting the drum or the lid, I cut the top 3 inches off the Weber Kettle bottom that I was taking the lid from. Then bolted the ring inside the drum with it sticking up a bit over the top of the drum. Weber lid fits on the Weber ring and everything works fine. Several other people have done the same. I used a jigsaw to cut the kettle.

The UDS topic came up recently (http://www.bbq-brethren.com/forum/showthread.php?t=119405)

Personally, I did cut off the lip on my drum with a cutoff disc & another brethren welded a small round bar around the lip and I ground off any rough edges.

Did you try your lid on the bottom of the drum? Wish I had tried this first.

I put the drum I got an a solid floor. set the lid on it and jammed it on as tight as I could get it, then I used a piece of 2x4 block and hammered the rim edge all around. That eventually spread the lid rim outward enough to form to the wider diameter of the drum. I then ground a angle on the outside of the drum rim to give my lid some room to fit down but not be stuck on, so it would lift off the drum with out being difficult yet the lid is sealed pretty well, since I didn't mess with the rim top edge.

Add a small piece of sheet steel on the inside of the top edge of the drum around the opening...A bead of high temp gasket material between the metal flange and the barrell and a couple sheet metal screws and your done, problem solved....

Mine was close enough to fitting that I ran a grinder around the rim of the barrel a few times just enough to shave off enough medal for the lid to fit how I liked it.