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Outdoor Stone-Kitchen Bar and Grill Stone masons Derek Stearns and Dean Marsico turn a plain backyard barbecue into a distinctive outdoor kitchen. From "Rock Solid" episode DROC-301

In this Rock Solid project, real-life stone masons Derek Stearns and Dean Marsico install a beautiful outdoor bar and grill in a fraction of the time it would take to cut the same stones by hand.

Following are the basic steps that Dean and Derek followed in the project featured in Rock Solid, episode 301, as well as lists of tools and materials that were required.

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	Before
	After

Do-it-yourselfers can now install their own outdoor stone kitchen using a unique kit created by New World Stoneworks. The stone kit is custom designed and comes with pre-cut and numbered stones so it goes up fast and easy.

Tools:

trowel
stone hammer
tape measure
2-foot level
4-foot level
square
safety glasses
wheelbarrow
shovel
rake
pencil
grinder
rubber mallet
jointer

Materials:

stone kit
cement brick
concrete for footing
mortar

Note: The quantities needed for each of these materials vary with application. For your specific project, Dean and Derek suggest taking the dimensions to a local dealer, where they will calculate the amount of each product needed.

	Figure A
	Figure B
	Figure C

Design and Materials

New World Stoneworks can custom design the outdoor kitchen to the specifications of your site. You'll be able to see the stone pattern and final look of the project before a single stone is cut. Dean and Derek decide to replace the old, rundown grill and countertop by the fence with a stone kit that has a grill and refrigerator and room for seating.

Preparation for the Footing

• Dean and Derek first remove the old grill from the site and then lay down the template (figure A). The template is included in the kit and is a footprint for the base unit.

• Place the template in position and walk around it to be sure there is space where appliances will open. This also allows you to clearly mark where gas, water, or electrical services need to go. Here, a hole has been cut for the gas line (figure B).

• Once the template is set exactly in place, trace it with a pencil (figure C). You'll need to dig down six inches for the footing.
  

  	Figure D
  	Figure E

• Dean and Derek have to cut through the stone pavers first, so they use a grinder with a diamond blade to score an outline (figure D).

• After removing the pavers in the center area, they cut a deeper line (figure E) and separate the pieces by tapping them with a stone hammer.

• To make sure that your cuts and footing are accurate, set the template down again. Derek recessed the line about a 1/4-inch inside the template, so that the stones will sit directly on the pavers and the footing will not show.

• Next, you need to dig the footing about six inches deep. Be very careful using your equipment around the gas line and other utilities. You might need to set up a form to make sure your footing is square when it dries. Dean and Derek use some pieces of wood to make the form and add stakes and old pavers to hold it in place.

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