Echoes, thanks for your kindness. You're absolutely correct; I got lazy and just tried to braze it straight. I was taught how to braze cast and should know better. They got the piece real hot and set it in a bed of sand to cool slowly with nickle rod, and even peened the weld with a ball peen hammer as it cooled to stop cracking. This time I'll bake the grate in the oven with it cranked or it might get even hotter set on clean. I'll have to move the pieces 20' to the bench without dropping them on my sneakers
There's one spot on the grate where the brass took very well. If I bake the grate I hope it won't oxidize where I need to braze, but I could clean off the areas real quick I guess.
Steve, another good idea, I could probably work with pine somehow. I was also thinking of plaster of paris or some kind of hobby mold compound. Gotta hit Ebay to see what kind of kits are out there.
Thanks for the replies, and links to guys that used rebar or bar stock.
This Monticello was designed to heat way more than my little place; not a champion design anyway, you have to open the ash door to shake.
also looked at woodsmanspartsplus and they have a few grates that might work out. Inside my stove is a welded ring that the grate and the brick sits on, 12-1/4" hole with a slot for the shaker handle.