Pull the old one out and bend the legs so it lays flat.
Use it as a pattern on top of a scrap of thin sheet metal.
First drill the holes then cut out the piece.
Bend the legs down and install.
Good as new.

 

Buy a new quality smoker......go for the stainless steel.

 

After you make the new screen per Harry's post maybe stuff more fuel in the smoker so it doesn't burn as hot. I have not burned through one yet. After lighting it each time I add pine needles I stuff it a bit harder until it is quite firm. Ideally the smoker stops smoking between puffs but comes back to life after a puff or two. This way the smoke is very cool as well. For fun, post pics when you are done....

 

I think it burned through due to two things. We're in the high desert in Southern Utah. It gets real windy here. Not a whole lot of fuel options and I've been trying a new thing. Rolled up cardboard. Smokes and burns real well.

I corked it last time and set it outside. Wind came up. Next time was when I found it burned out. The roll of cardboard was all ash. I think the wind was able to get into the smoker, get it hot, and keep it going.

 

Not a whole lot of fuel options and I've been trying a new thing. Rolled up cardboard. Smokes and burns real well.

I corked it last time and set it outside. Wind came up. Next time was when I found it burned out. The roll of cardboard was all ash. I think the wind was able to get into the smoker, get it hot, and keep it going.

I've used rolled up cardboard for years. Lately I 'buy' the one-sided rolled stuff like in the link below. I use the 12 in. X 250 foot roll and roll a diameter that fits my smoker......then cut the 12 in. roll in half to make two 6 in. loads for my smoker. They work great, and are easily lit with a propane torch before dropping it into the smoker.

Corrugated Wrap 12" x 250' x 1/8" Thick - B Flute - Cardboard Wrap | eBay

Find many great new & used options and get the best deals for Corrugated Wrap 12" x 250' x 1/8" Thick - B Flute - Cardboard Wrap at the best online prices at eBay! Free shipping for many products!

www.ebay.com

 

On mine, only the central area burned through, so I cut-up a piece of steel mesh (what you guys call #8 hardware cloth) to roughly the same internal diameter as the smoker, and simply dropped it in. That was - what ? - 8-10 years ago. No problems since that time. Carbon build-up has kept it in place. An easy quick fix.
LJ

 

That's what I have in there now at a 'temporary' fix. Maybe it will become more permanent.

 

Go to Home Depot, Lowes or somewhere similer and go to the plumbing aisle.

There you will find snap-in shower drain covers.... THAT is what those are in the bottom of smokers. Something like this one, but the original is a super-cheap version:

DANCO 4-1/4 in. Snap-In Shower Drain 89088 - The Home Depot

You don't need the strainer, by the way, but there it is, if you prefer to have it.

 

Yes, I enjoy fabricating things myself. But when the grate finally burned out of my 30 yr. old Dadant smoker, I just picked up the phone and they shipped me a new one.