How to Make a Welding Barbecue - ✔️ Welding Projects

How to Make a Welding Barbecue


How to Make a Welding Barbecue. This is dedicated to Steveastrouk’s kindness in teaching us (Perryscope and me) the fundamentals of welding and donating the equipment and materials needed to complete this project.

He even delivered the meat.

Step 1: Before Welding, Learn How to Weld.

We needed the knowledge and tools to put the BBQ together before we could do so.

Steveastrouk assembled a fantastic TIG welding kit with masks and gloves, scrap metal, and a massive cast-iron bench to work on.

We discovered:

Take things slowly.

TIG welding causes sunburn.

Make sure you have a solid foundation.

Keep the amps as low as possible.

The temperature rises when the tip is moved away from the workpiece.

Allow the working end of the welding rod to come into contact with the welding tip while the distant end is in contact with the “ground.” The current earth through the rod makes it too hot to let go.

Step 2: MakeConstructing the Grill Frame

We already had a spare oven grill to work with, so we used it to measure a frame out of a 1″ box section. And joined the four sides using welding.

We welded across the junction on both sides of the frame after “tacking” the corners.

Step 3: Make the Ash Catcher/Heat Reflector

Making the Ash Catcher/ Heat Reflector

When it’s time to make the ash catcher, the benefits of working in a well-equipped workshop truly hit home. This is constructed from a single sheet of steel. We discovered some stock that was too large but easily trimmed down to size using a large sheet cutter. With tasks like these, mark the length on the frame and cut. I don’t believe we measured anything precisely. This was a short process because we had access to a large sheet metal cutter. However, you may use an angle grinder if you do not have access.


We acquired a huge pipe and utilized it as a form to pull the steel into a highly accurate parabola shape that was best suited to maximize heat reflection. That was a fluke; we bent it till all sides fit on either side of the frame.

This was then welded in place on top of the frame. To begin, place some tacks in the corners to reduce warp.

Welding at the right angle was much more complicated than welding in the butt-joints. The welder’s arc seemed to drift from side to side, and it was challenging to balance the heat pouring into the thicker square piece and the thinner plate. The plate burned through remarkably quickly…

Step 4: Welding Square Mesh on Both Ends

Next, we placed the frame on its side and welded a piece of 1″ steel square mesh over the end, which overlapped the ash tray. The overlap was removed with a grinder, and any sharp edges were smoothed.

(After the barbeque was already in use, we realized that a piece of the plate would have helped to keep the ashes contained.) Of course, it’s a little late now…)

Step 5: Create the Legs

We held the grill at a comfortable height and measured the diagonal distance to the floor with some leftover welding rods to determine how long the legs should be. It should be fine as long as all four legs are the same length. These were cut using the metal band saw once more.

To secure the legs to the frame, we used M8 pronged Tee nuts and bolts. The Nuts were ideal because they had broad flanges connected and fit precisely in the ends of the 1″ box section. We had a beautiful countersunk nut to attach the legs to after four tack welds.

We created some basic 1″ washers out of leftover 1″ offcuts for two legs. These were required for the legs to cross.

The legs were fitted and leveled with a spirit level before marking the center point for the bolts holding the two legs together where they crossed.

These were drilled, and M8 bolts with washers were inserted.

Step 6: Installing a Mesh Tray to Hold the Charcoal

We measured the Mesh’s length and used the angle grinder to cut off to the nearest strip, leaving a spiky edge to interleave with the ends and lock the trap in place.

Step 7: Turn on the lights and have fun!

The form of the ashtray, together with the excellent air flow, help reflect heat back to the charcoal, and the charcoal was blazing white, and the grill was quite hot!

The grill we were using had inconveniently wide gaps for food to fall through, which Lemonie fixed by weaving stainless-steel welding rods through the grid.

Read More: Beginner Welding Projects