Materials	Special Equipment
4 Aluminum Sheets 20.5” x 12.5”	Rivet Gun
4 Aluminum Sheets 18.5” x 12.5” 12 Rivets (medium size)	Tin Snips (Tin or aluminum cutter) Flat Metal File Rounded Metal File

 

                                                              
                                                         
   

                                                       
                                                    
                                                                                                           
Procedures
HLB Heat Shield:
Cut four aluminum sheets, 2 – 20.5”x 12.5” and 2 – 18.5” x 12.5”, using tin snips.
Tip: Mark the sheets with a felt-tip pen and straight edge for cutting.
Lightly file the edges to avoid cutting yourself.
Mark and cut out the 5”x5” view hole using a drill and tin snips.
Mark folding lines 1.0” from each end on front and back sheets.
Mark and drill 3 centered rivet holes on each end as shown above. (Total of 12)
Bend the 4 ends to a 90-degree fold as shown above.
Remove the 4 carriage bolts, which will secure the heat shield to the frame.
Assemble the 4 sheets into postion on the frame
Mark and drill the 4 holes for the carriage bolts.
Bolt the back and front sheet to the frame.
While all 4 sheets are aligned, mark the rivet holes on the side sheets.
Remove from the frame, drill rivet holes and insert rivets.
Bolt the completed heat shield to the frame.
 
Kettle Heat Shield:
Exactly the same procedures.
 
Heat Shield Performance
I tested the burners before installing the heat shielding.  As I suspected, the four sides of the framing 3” from the burners became quite hot.  Since building the shields, all sides remain cool.  The aluminum & plywood platform that the burners rest upon get only slightly warm.  The aluminum sheets under the burners, added at Step 2, Burners and Gas Lines, help to insulate the platform from heat.
 
If you would like to eliminate the heat shielding, redesign the frame with at least 6” between the burners and frame.  Six inches because when testing the burners without the shielding, I noticed that the corners of the frame, which are 6” from the frame, didn’t get hot.  Or, redesign without a wood frame next to the burners.  But I’d suggest keeping to my plan because six inches on all sides would create an over-large system and the frame acts as a protective barrier to wind and the burner’s heat.