DIY Network

Barbecue Stand and Assembly Barbecue Stand and Assembly From "Trade School" episode DTRS-103

In this segment, Conor crafts the stand, joins it to the barrel and finishes the barbecue grill ....

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Basic Tools:

MIG welder
Plasma cutter
Oxyacetylene torch
Square metal tubing
Disc grinder
Sheet metal break
Tape measure
Bevel T
Combination square
Steel Square
Squaring magnet
Ironworker
Clamps
Chop saw

• Conor begins this phase by measuring and cutting several pieces of square metal tubing on the chop saw to create the legs and side shelves that form the stand (figure A). Cutting on a chop saw creates a lot of sparks! He cleans up rough edges using the disc grinder (figure B).

  Figure A

  Figure B

  
  

• To give the grill mobility, he mounts wheels on two of the stand legs. He uses two 4-inch metal rods to serve as axles. He inserts the rods through pre-drilled holes in the tubing and welds them in place (figure C). He secures the wheels to the axles with cotter pins (figure D). Because adding the wheels increases the overall length of this half of the stand, Conor needs to ensure the opposite half is long enough to compensate.

  Figure C

  Figure D

  
  

  Figure E

• Next, Conor assembles and clamps the frame pieces to the platten table. He tack welds each side together utilizing the squaring magnet to hold upright pieces in place (figure E).He completes the two halves of the stand with a solid weld along the seams.
  

• Conor aligns and clamps the wheeled half of the stand to the barrel and tack welds it in place (figure F). He follows this up with staggered 1-inch welds along the seams. Then, using a prop to keep the grill level, he welds the other half of the stand, (figure G). The grill can now stand on its own.

  Figure F

  Figure G

  
  

• Using the plasma cutter, Conor cuts 11-gauge sheet metal to create the upper and lower shelves. To fit the lower shelf in the stand, he cuts the corners of the metal at a 45-degree angle (figure H). He then welds these in place (figure I).

  Figure H

  Figure I

  
  

• Conor uses stainless steel mesh for both the cooking surface and the charcoal shelf. After measuring the interior of the grill, he cuts the basic shapes using the plasma cutter and straightens the edges on the ironworker (figure J).He inserts U-shaped handles made of bent stainless steel rods through the mesh and welds the handle ends to a flat stainless steel plate (figure K).

  Figure J

  Figure K

  
  

  Figure L

• To hold the mesh surfaces within the grill, Conor welds four pieces of angle iron into rectangular braces. He reinforces the braces with steel cross beams. Then, he aligns and clamps the braces inside the barrel and welds them in (figure L).
  

• Conor fabricates two hinges to join the base and lid of the barrel (figure M). To create each hinge, he first welds square steel plates to the bottom half of the barrel. Then, using an oxyacetylene torch and a mallet, he heats and bends a steel rod sheathed in steel tubing until achieving the desired U-shape. He welds the ends of the rod to the steel plates and welds the steel tubing to the lid of the barrel. The hinges allow the lid to open and close freely. He also welds a triangular piece of steel to create a stopper.

• To create the main lid handle, Conor secures a piece of square steel rod in a table vise and heats it using an oxyacetylene torch. Then, using a ratchet wrench, he twists the handle several times. He welds the ends of the handle to the lid (figure N).

• To finish the grill, Conor paints it with high-temperature black spray paint.

Figure M

Figure N

In the next segment, Conor crafts a road-worthy utility trailer ....