How To Build a Grill Out of a 55 Gallon Drum

• the 55 gallon drum barrel (Make sure the drum is new or has been used for holding a food substance like vegetable oil and not for poisonous or hazardous substances like normal oil.)


• 2 metal hinges (so you can attach the top half as a cover)


• 1 or 2 metal handles with bolts and nuts (to attach the handles which purpose are to open and close the grill)


• 2 chains so the top will not open too far


• 22 Inch diameter stainless steel barbecue grill ) has to be cut a little bit smaller than the inside dimensions of the barrel so it can be placed a little bit inside the drum)


• a metal grid a little smaller than the grilling surface (to place beneath the grilling grid) so you don't have to fill the whole drum with charcoal


• Metal to use for the stand like steel rods (e.g. angle iron or steel reinforced bars)

You also need tools like a welding device, a saw used for cutting metal, a hammer, and tools to attach the bolts and hinges. And of course safety equipment like ear plugs, a welding face shield and gloves and safety glasses.

courtesy photo by Photo Mojo

Start with building a fire inside the barrel to clean it. Make sure the inside of the barrel is free of any dirt or substances by cleaning it afterwards with water without soap or anything. Keep in mind to wait until the barrel has cooled down before hosing it with water.

(courtesy photo by Laser2k)

Cutting the barrel
The most convenient way to accurately cut the barrel in half is by using a plasma torch. If you don't have one you can also use a reciprocal saw / sawzall. These are less expensive and will do the job as well. In order to cut the barrel accurately masking tape can be used as a sawing guide by applying it over the length of the drum. First measure the center of the drum and mark it, then you can line out the sawing direction with the tape.

Air vent holes
This is also a good time to drill a few holes (preferably two, one at each side) of the bottom half of the barrel. Remember to keep in mind which half you use for the bottom.

Attach a thin piece of metal with a screw just next to the holes you have just drilled. You can use small scraps of steel or round can ends as the air vent covers. This way you can move the metal over the hole thus adjusting the air flow and regulating the temperature inside the grill.

(courtesy photo by Sugarcreekphoto)

You can buy inexpensive simple hinges and handles at your local hardware store. The Rods have to be placed at the desired height of the grilling surface. One way to do this is by welding bars on each end and optionally two supportive ones in the middle.

Another way is to cut the grill just a little smaller than the half barrel itself, this way the grill grid will sink a little in the half barrel and will fit automatically. But the grill grid will fit better by placing rods. This way it is less likely to dislocate.

Bolt the handles to opposite sides of the lid through holes you have drilled already in the grill lid.

In addition you can also make air vents into the drum and lid to control the temperature.

You can use a shopping cart although that's illegal unless you are able to buy one somewhere.

Another solution is to weld a stand yourself. You can make a steel frame of angle iron. The height of the grill should be about waist level. Make sure the frame is stable. You don't want your steaks to end up in the grass.

The video below shows in detail how to build a framework for the grill.

Although it is not really necessary you can paint your new built grill with high temperature paint like e.g. Char-Broil high temperature grill paint. This will not only add to the overall appearance of the BBQ but it also protects the metal against rust and weather influences.

Now you know how to make a charcoal grill and you have built it it is time to fire it up and start cooking!

Connoisseurs say grilling on charcoal is the real thing. The coal adds a lovely flavor to the food which you'll never get on a gas grill.

While charcoal gets hotter than gas it also has the tendency to burn unevenly. While some parts are almost grey and thus ready, others are still burning hot red. So it takes more dedication and skills to cook on charcoal than on gas. One essential technique is the difference between direct and indirect grilling.

Here are a few charcoal grill lighting tips:

• The amount of charcoal you need depends on what you are going to cook. One layer for steaks and burgers and two layers for chicken and roasts.


• Stack the charcoal into a pyramid shape.


• Pour lighter fluid over the charcoal, add more to the center than the edges. It's recommended to use about 1/4 cup to 1-pound charcoal.


• Wait for about 30 seconds so the fluid can saturate the coal.


• Light at least two sides from the bottom on with a long match.


• Let the charcoal burn until it's blazing red. Then use tongs or a spatula to spread the coals over the bottom


• Wait until the charcoal is white on the surface


• Close the lid and wait 5 minutes before you start barbecuing

For extra safety you can buy self lighting charcoal briquettes. These are already soaked in lighter fluid.

Here are a few BBQ cleaning, cooking and safety tips:

• Cleaning the grill before each use reduces the smoke and coal rests that can leave a bad taste on the food.


• Do not cook on a too hot or not hot enough barbecue fire. You can check the ideal temperature by holding your hand about 6 inches above the coals. If you can count slowly to three before having to pull your hand away, the fire is the right temperature for direct grilling (about 500°F).


• (Probably unnecessary to say but for the sake of completeness:)Never add lighter fluid to burning coals. Even if there is no flame the heat will vaporize the lighter fluid and this can cause a dangerous flame immediately when the vapor encounters a flame.

on a hot shrimp or the grill itself? Healing Manuka honey offers immediate relief.

In this comprehensive 19 steps guide they also use a 55 gallon barrel but this time only a quarter is cut out of the barrel. With clear explanations and many photo's this is a very good DIY grill tutorial.