How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
Thank you for making this Instructable one of the Best of 2009! #7 in the Food Category...

Lucky for me on my last day of work at The Bakery, the 55-gallon honey barrel I'd been waiting for was finally empty. Getting laid off wasn't going to stand in the way of my dream to make my own barbecue.

Step 1: The Prep

How to Build Your Own BBQ Barrel
First, I had to empty out all the excess honey and clean the inside (not exciting enough for a photo). Then I borrowed a grinder from a friend and cut the opening.

It's way less of a hassle to have a food grade barrel. Imagine bbq'n in a barrel that use to have oil or fuel. Yuck!

Step 2: Constructing the stand

How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
I had to make a base and the only things around were some old chain-link fence posts that I'd never taken to the dump and some scrap plywood I'd demoed out of a creepy room in my basement.

I cut 6 posts at different lengths - 2 the length of the barrel & 4 for the legs. I wanted to bbq to be portable so the best way for that was for the barrel to sit on top of the stand. Two posts held the barrel while the 4 legs were attached by drilling holes for the carriage bolts on either end. To attach keep the legs sturdy I secured them with pieces of plywood. Put the barrel on top and it stood tall and proud.


Step 3: Attaching the lid & grill grates

How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
I added brackets to hold the grills and to keep the lid from falling inside, as well as a lower rack to hold the coals and allow for air circulation.

Be sure to purchase stainless steel brackets and hinges. If you buy galvanized you should take a torch to it to burn off the fumes that will be there the first couple times you grill.

Step 4: Burn off the inside

How to Build Your Own BBQ Barrel
I lit a fire in it to burn off any paints or coatings or who knows what. There may or may not have been a burn ban going on this day so I made burgers on my gas grill to disguise the smoke.

Step 5: Finishing Touches

How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
How to Build Your Own BBQ Barrel
Last steps in the construction were to add a handle (plain wooden dowel from the hardware store), air vents, and a temperature gauge. I also decided to spray the barrel with a high heat resistant pant. Besides customizing the color a little, the paint helps prevent rust on the barrel. The only thing left was to test it in a real-life BBQ situation.
 
 

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