who says how big

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I prefer 5mm +. The 4mm seems more like a sheet of plastic to me and not enough gear getting through so the two coats become one. If the 4mm works then more strands the better.

i would like to know why Weber insist on vertical and horizontal strands of mesh? Surely on a two coat system one V & H in the base and another mesh 45 degrees at the stress points in the second coat?

Think of stress cracks stemming from window sill corners. 45 degrees? What strength does a V & H mesh have to offer?
 
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