The steel charcoal pan on my Okalahoma Joes Table Top grill is rusting out. A replacement is 50 bucks. I am planning to repair the pan with some aluminum plate I have on hand. Is there any health hazard involved with cooking with an aluminum charcoal pan?

I know this is an odd question for a motorcycle forum but a lot of you guys seem to know about everything. And I don't really want to join a grill forum. 

This will give you a chance to explore the melting point of aluminum.

https://www.wikihow.com/Is-Aluminum-Cookware-Safe


Sounds like you won't be using it for direct cooking but it will get hot enough to gas off though or possibly melt as George has suggested.  If it were me, I wouldn't use it.  I have seen non-Aluminum 'grid' material for sale in hw stores and I have used that as a base for my chimenea when the original grid burned out.

Thanks for the advice, I will look for some steel.

Hello
to avoid rust and to keep warm, use stainless steel 

I'd just drop a piece of sheet steel in the bottom of the pan and run that until it rusts through, then repeat. You could probably commission a stainless steel pan for about $100 from a local fabricator.

I'm headed to Tractor Supply. I noticed they had a good lookng supply of metal plate. The charcoal pan for this rig is perforated with a removable ash pan underneath, so I'll have to do some drilling.
Thanks again for the tips.