How to Build a Charcoal Grill Out of a 55 Gallon Barrel
- 1). Put on your safety gear. Mark your cutting line with masking tape and cut the barrel in half lengthwise with the Sawzall. You should be left with two even halves.
- 2). Drill four small ventilation holes, 1/8 to 1/4 inch, in the grill's bottom half. Place two holes on each side of the barrel, near the bottom. These will draw air in to feed the charcoal flame. Cut the ends off the aluminum cans with a hacksaw or tin snips, then cut the can lengthwise so you can unroll it into a sheet of aluminum. Cut small aluminum strips that will fit over the holes and secure them with a screw at one end. Swing these little strips over your ventilation holes to control how hot your fire gets.
- 3). Attach two handles, one on each side of the bottom half, near the lip. Attach two more, evenly spaced, on the front of the top half, which you will lift to open the grill. Place the hinges an equal distance apart and attach them where the two barrel halves join together on the back. The top half should now swing cleanly open.
- 4). Open your grill so that it forms an angle slightly wider than 90 degrees. Measure from the top center of the bottom half to the top center of the top half, and use the Sawzall to cut the chains to the resulting length. Secure the chains to each side, on the outside of the grill, and make sure the grill can close without catching the chain inside. The chain should be taut when the grill is fully open, and the grill should be able to rest open without swinging open any wider or slamming down on your hands.
- 5). Measure how high you want the grill to stand off the ground and cut four lengths of angle iron to that length. These will be your legs. Make sure to maintain the correct angle for the grill's opening; you may need different lengths of angle iron for the front and back legs. Weld each leg to a corner of the grill's bottom half. Measure diagonally between the legs and cut the remaining lengths of angle iron to match each measurement. Weld these lengths of angle iron in a diagonal pattern to cross-brace the legs.
- 6). Clean the grill. Fill the grill with wood or charcoal, light it and close the lid. Let it burn out and wait for the grill to cool, then clean the inside with soapy water. Rinse and let dry.
- 7). Cut a rectangular section of wire mesh that will fit snugly inside the bottom of the grill above the ventilation holes. This will hold your charcoal and allow the ash to sift down into the bottom. Next, measure the inside of the grill from front to back and drill four evenly-spaced holes at the bottom, where the wire mesh will sit, and four at the top, at the appropriate height for your grill rack. Make sure the diameter of the holes matches that of your metal rods. Cut the eight metal rods to be slightly larger than the length of the grill and thread them through the holes. Place the wire mesh on the lower set of rods and the grilling surface on the higher set of rods.
- 8). Optional: Remove your cooking surfaces, close the grill and paint the outside with a heat-resistant spray paint. This will give your grill a nice shine, and make it look professional and presentable.
That's it! Light it up and grill some meat. You've earned it.
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