HOW TO BUILD YOUR OWN 55-GAL. BARREL BBQ*

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There’s nothing better than the high octane performance of a flaming charcoal barbecue– and there’s nothing cooler than manning your own 55-gallon barrel grill, made with your own hands. Here’s a cool tutorial we found on the Super Chevy website. Hey, summer’s coming, dude. Let’s talk about how you can make this a reality.

Things You Will Need:

barrel - found

  • Find a 55 gallon drum. Sometimes you can avoid buying a new one by checking out Craigslist or other local classifieds, pet shops or weed n’ feeds. The best kind of 55-gallon drum barrel to get is food related. Try to avoid one that housed toxic chemicals, but if you’re not sure what it contained, you’re going to want to burn it clean when you cut it open. 

barrel - taped

  • Rather than cutting the barrel in half, we’re going to show a clam shell it with a quarter cut. With the masking tape and a level, set all your lines ready to cut.

barrel - cut

  • The next step is to use the trusty cut-off tool and cut down the side of the barrel along the blue tape. The cut off quarter is going to be the BBQ grill’s lid. When you’ve cut out the quarter section, build a large fire inside of the barrel to thoroughly burn out any lingering harmful substances. Then, once cool,  dump the ashes and give it one last thorough hosing.
  • Next, take some angle iron and weld a rectangular shape out of it. Then weld it into place in the middle of the drum. This will provide as a rest for the grill.

barrel - mesh

  • Find a good mesh that can be used as the grill surface, preferably a heavier gauge metal, and one where the edges are flattened so there are no sharp points sticking up. If you need to flatten the sharp edges yourself, that’s what the grinder is for. Here they welded 1/8″ metal rod all along the edges and eventually added some cross bars as well. Besides not getting gouged every time you BBQ, it also makes it easier to scrub after grilling. 

barrel - stands - relief cuts

  • Take two lengths of 1/2″ box tube and make relief cuts every two inches so you can bend them to the shape of the barrel. Then bend it around the barrel.

barrel - stand - relief welded

  • Once you’ve got the shape you desire, weld the cuts smooth with your 70 amp stick welder. This creates a sturdy cradle on which you’ll be attaching the legs.

barrel - stands welded on

  • Then weld the half moon shapes to the ends of the barrel. They should make a nice snug fit.

barrel - hinges

  • Attach hinges to the barrel and lid, and reinforce it with steel plates on the inside to ensure a long-lasting, sturdy hinge.

barrel - on legs

  • Determine how high you want your grill to be (3-ft. is good) and accordingly cut the 2×1 square tubing into legs. Cut relief marks about 6″ down the legs so you can bend them outward for greater stability. Now weld on the legs, and you have your very own, cheap and efficient 55-gal. drum grill!

barrel - complete

Of course, you’ll probably want to add handles, a couple of vents, a hole on the bottom for dripping. If you came this far, though, I trust you can take it from here.