How to Make a BBQ Grill Using a 55 gallon drum

Creating a BBQ grill from a 55-gallon drum can be a fun and rewarding project. Here’s a general guide on how you can accomplish it.

Please note, this is a general outline and details may vary depending on your specific drum and requirements. Always ensure you are working in a safe, well-ventilated space, and wearing the appropriate safety gear when cutting or drilling into the drum.

Materials:

1. 55-gallon steel drum
2. Steel grate (for cooking surface)
3. Steel pipes and fittings (for legs and handle)
4. Hinges
5. Latch
6. High-temperature paint (optional)
7. Air vents
8. Drill
9. Jigsaw or reciprocating saw
10. Welding equipment or bolts (for assembly)
11. Angle grinder
12. Steel wire brush
13. Tape measure
14. Marking tool

Instructions:

1. Safety First: If the drum previously contained chemicals, it needs to be thoroughly cleaned and any residues burned off. This can be done by filling it with wood and safely starting a large fire. Leave it burning for a couple of hours. Remember to do this in a safe and ventilated place, as harmful fumes may be produced.
2. Design: Measure and mark the section of the drum you will cut to make the lid. It’s generally a good idea to cut it lengthwise leaving one-third of the barrel as the lid and the other two-thirds as the body of the grill.
3. Cut the Drum: Using a jigsaw or reciprocating saw, cut along the lines you have drawn. Remember to wear your safety gear.
4. Smooth the Edges: Use an angle grinder to smooth off the edges where you’ve cut, to prevent any potential injuries.
5. Install the Grate: Measure the interior width of the drum to determine the size of the grate you will use for grilling. You can either weld or bolt supports for the grate about 8-10 inches from the bottom of the drum. Place the grate on the supports.
6. Install the Legs: Depending on your design, you can use steel pipe and fittings to create a sturdy set of legs for your grill. Weld or bolt the legs onto the bottom of the drum.
7. Add the Lid: Attach the lid to the body of the grill using the hinges. Ensure the lid can open and close smoothly. Install a handle on the lid, making sure it’s made from a non-heat conducting material or a material designed to remain cool.
8. Ventilation: Drill a few holes in the lid and body to serve as air vents. This allows for airflow and temperature control inside the grill.
9. Final Touches: Use high-temperature paint to make your grill look aesthetically pleasing and to add a layer of protection against the elements.
10. Test It: Light a small amount of charcoal in the drum to test the air vents and see if you can control the temperature.

That’s it! You now have a homemade 55-gallon BBQ grill. Happy grilling!