My old BBQ drip tray was in really rough shape:

In exchange for coffees, the installer of our new energy efficient (and functional!) air conditioner gave me a nice new piece of sheet metal, so I’m traced out a new drip tray:

Here it is before any folds:

I don’t have a brake, nor access to a metal shop, but Sofia bought Lance a little vice a few Christmases ago, and I borrowed that:

I also found that a heavy ruler (one of the edges of my square), worked well to help with the bends

The very skinny bends were harder to do nicely, and I had to resort to some pliers to help coerce them into place, but the final result is pretty decent and a lot less porous:

It looks a bit out of place with all the rust in the remainder of the BBQ, but should help give the unit a few more years: