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  #1  
Old 02-11-2012, 10:45 AM
FX4 FX4 is offline
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Default BBQ Build Thread

What started this whole project is that I host something I call Rib Fest every year for friends/family. Well last year was my biggest turn out with about 25 people and 40lbs of ribs..... it took forever to get everything ready with 3 different bbq's.... so I decided to build one big one! I have been working on this for a couple hours a night for the past week or so. I guess you can call it a little involving. Total spent so far is $10.00 which is the best part! I have no fancy equipment and since I'm rebuilding my chop saw, everything was cut with a 4.5" angle grinder, and bent by hand with a vice and a hammer.

Anyway here is where the build started:
Found a 55 gallon barrel, cut out an opening for the door, welded a piano hinge for the door (where my $10 was spent):






my poor welding (this was my first time welding sheet metal and it was def. a learning experience):



welds grinded down a bit:




cut out bottom grate for the charcoal:




welded on a smoke stack (still need to figure out how I'm going to cap it), it's 2.25" mandrel bent exhaust tubing :





welded in brackets for bottom charcoal grate and top food grate:




Here is my air/temp control welded up at the bottom:



Had to tack on some rod to the door as the metal is thin, the door bent everytime you tried to open/close it. This made it much more sturdy:



Modified one of the 2 wood racks I have built previously to fit the bbq and added some brackets for the front ledge:







Still need to do list:
-finish grinding all welds
-burn it out
-finish welding legs
-purchase:
-paint
-temp. gauge
-wood for shelving
-smoke stack cap
-food grates (I'm opting to purchase the nice ceramic coated grates for the food)
-larger casters


Any suggestions/ideas will be appreciated. To add to the handle on the door I'm going to buy a wooden dowel and cut in down the center and place each side of dowel on each side of the steel handle to keep my hand from burning when touched. I was also going to paint it a different color than bbq black, but after seeing the prices of the color cans... it's getting painted black! Thanks for looking

Rafal
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  #2  
Old 02-11-2012, 11:03 AM
Muscleford Muscleford is offline
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Default Re: BBQ Build Thread

What was originally in that barrel? There could be remains of some hazardous chemicals in nooks and crannies that may taint what your ribs.
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  #3  
Old 02-11-2012, 11:09 AM
FX4 FX4 is offline
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Default Re: BBQ Build Thread

Quote:
Originally Posted by Muscleford View Post
What was originally in that barrel? There could be remains of some hazardous chemicals in nooks and crannies that may taint what your ribs.
it was cooking oil, so it is a "food safe" barrel. It was sitting outside for quite a few months and will need to be burned out with wood and an actual fire before being painted and used. I wasn't about use a hazardous barrel so I start growing a third eye or something, . Also, everything welded on to it is stainless steel and not galvanized or aluminized steel or anything like that.
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  #4  
Old 02-11-2012, 11:09 AM
01_ranger_4x4 01_ranger_4x4 is offline
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Default Re: BBQ Build Thread

Nice set up! The vent holes in the temp control look a little small though
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  #5  
Old 02-11-2012, 11:15 AM
FX4 FX4 is offline
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Default Re: BBQ Build Thread

Quote:
Originally Posted by 01_ranger_4x4 View Post
Nice set up! The vent holes in the temp control look a little small though
I was thinking the same thing today, they are 1/2", but I know i'm going to need to pick up a 3/4" bit and drill them out bigger... because the way I have them drilled out now, after measuring 3/4" is the biggest I can go with.

Rafal
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  #6  
Old 02-18-2012, 03:15 PM
FX4 FX4 is offline
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Default Re: BBQ Build Thread

Made some more progress on the BBQ:

Cut a 1" wooden dowel in half and wrapped the handle:



Fabricated and welded the side shelf on:



Cut pieces of 1x4 to length and bolted them on:



Found a 2" pipe cap and welded it together on the smoke stack (you can't see it in the pictures, but there are 3 steel rods welded to the cap and the stack leaving a 1/2" space between the 2):




Here it is at it stands today:




I also ended up making the air vents bigger with a 3/4" holes, and added another piece of flat stock under the hinge as it was still binding when closing.


Now should I add 4 4" caster to the bottom, or simply do 2 6" cart wheels mounted on a rod on one side, and some little legs on the other like most bbq's?


Rafal
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Last edited by FX4; 02-18-2012 at 08:07 PM.
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  #7  
Old 02-18-2012, 03:59 PM
HazardousRanger HazardousRanger is offline
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Default Re: BBQ Build Thread

sick lol much cheaper than buying a bbq haha
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  #8  
Old 02-18-2012, 04:02 PM
Muscleford Muscleford is offline
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Default Re: BBQ Build Thread

Looking good. Nice work
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  #9  
Old 02-18-2012, 04:18 PM
pooleo pooleo is offline
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Default Re: BBQ Build Thread

looks legit. I want to make one some day too
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  #10  
Old 02-18-2012, 06:53 PM
Smasher Smasher is offline
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Default Re: BBQ Build Thread

I would do the (2) 6" casters and some legs on the other side to make it even. Then you know it won't roll away on you if you leave it alone for a moment.

Looks good though.
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  #11  
Old 02-18-2012, 06:59 PM
Redneckstone Redneckstone is offline
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Default Re: BBQ Build Thread

instead of the cap for the exhaust lol


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  #12  
Old 02-18-2012, 08:06 PM
FX4 FX4 is offline
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Default Re: BBQ Build Thread

^^^^^ I wanted to find something like that, but couldn't find it in a 2" version....

Rafal
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  #13  
Old 02-19-2012, 09:04 PM
01B3000 01B3000 is offline
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Default Re: BBQ Build Thread

Are you gonna make us a FRF cook book? Looks good
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  #14  
Old 02-21-2012, 01:36 AM
skulldrinker skulldrinker is offline
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Default Re: BBQ Build Thread

What kind of welder were you using?
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  #15  
Old 02-21-2012, 05:24 AM
dixie_boysles dixie_boysles is offline
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Default Re: BBQ Build Thread

awesome! paint the outside with some BBQ black heat paint! or some fire engine red engine paint
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