DIY Delight: A Comprehensive Guide to Building Your Own Outdoor Barbecue

There’s nothing quite like the sizzle of a barbecue on a warm summer evening, the aroma of char-grilled food filling the air, and the laughter of friends and family gathered around. But what if you could enhance that experience by building your very own outdoor barbecue? It’s more achievable than you might think, and this comprehensive guide will take you through every step, from planning to the first delicious meal cooked on your creation. Whether you’re a seasoned DIY enthusiast or a curious beginner, this article will equip you with the knowledge and confidence to build a barbecue that perfectly suits your needs and style.

Before You Start: Planning and Preparation

Before you even pick up a tool, careful planning is crucial for a successful barbecue build. Here’s what you need to consider:

1. Location, Location, Location:

• Safety First: Choose a location that’s a safe distance from your house, trees, fences, and any other flammable materials. Consider prevailing winds to avoid smoke drifting into your windows. A minimum of 10 feet from any structures is generally recommended.
• Level Surface: Ensure the ground is level and stable. Uneven ground will make construction difficult and can be a safety hazard. You may need to prepare the ground by excavating a little and adding gravel for a solid foundation.
• Proximity: Think about how close your barbecue will be to your kitchen, dining area, and seating. Easy access is key for a smooth grilling experience.
• Sunlight and Shade: Consider the position of the sun during different times of the day. You might want a partly shaded location for those scorching summer afternoons.

2. Choosing Your Barbecue Type:

There are several types of barbecues you can build. Here are some popular options:

• Brick or Block Barbecue: This is the most classic and durable option. It involves building a structure using bricks or concrete blocks. It’s very customizable but requires more effort and skill.
• Metal Barbecue Grill: You can build a custom frame for a purchased metal grill, which can be more straightforward if you are not comfortable with masonry.
• Hybrid Barbecue: Combine elements of different designs, such as a brick base with a metal insert.
• Simple Fire Pit Style: A straightforward design for a fire pit barbecue, can be as simple as laying bricks in a circle, or more elaborate using concrete.

For this guide, we will focus on building a classic brick or block barbecue.

3. Design and Size:

• Determine Dimensions: Decide how large you want your barbecue to be. Consider the number of people you typically cook for. Measure your grilling grate to make sure it fits your design.
• Sketch a Plan: It’s helpful to sketch your design on paper, including all dimensions, to better understand the materials you’ll need and the construction process.
• Consider Features: Think about additional features, such as a side table, storage space for wood or charcoal, or a chimney for better ventilation.

4. Gathering Materials:

Based on your chosen design, you’ll need to gather the appropriate materials. For a brick or block barbecue, these may include:

• Bricks or Concrete Blocks: Calculate how many you’ll need based on your design. Consider choosing fire-rated bricks for the firebox.
• Firebricks: To line the firebox for added protection against heat.
• Mortar: For joining the bricks or blocks. Buy a premixed option to make the process simpler, or use a mix of cement, sand, and water.
• Grilling Grate: Choose one made from durable, heat-resistant material such as stainless steel or cast iron.
• Metal Support Bars/Angles: If needed for grates, or for creating a shelf to hold fuel.
• Foundation Material: Gravel, paving stones, or concrete mix for a solid base.
• Level, Measuring Tape, Spirit Level, Trowel, Gloves, Safety Glasses: Essential tools for the construction process.

Step-by-Step Guide: Building Your Brick or Block Barbecue

Now that you have everything planned and gathered, let’s begin the construction process:

Step 1: Preparing the Foundation

1. Mark the Area: Use stakes and string to mark out the exact dimensions of your barbecue’s base.
2. Excavate: Remove any topsoil and dig down a few inches (4-6 inches) to create a level foundation area.
3. Lay Foundation Material: Add a layer of gravel or crushed stone to provide drainage and prevent shifting. Compact the gravel with a tamper or by hand.
4. Optional Concrete Base: For added stability, you can pour a concrete slab on top of the gravel. Ensure it’s level using a spirit level, and let it cure fully before moving on to the next step.

Step 2: Laying the First Course of Bricks or Blocks

1. Dry Fit: Lay out your first layer of bricks or blocks on the foundation without mortar. This allows you to double-check your dimensions and make any necessary adjustments. Make sure the first course is square.
2. Prepare the Mortar: Mix your mortar according to the manufacturer’s instructions. It should have a thick, pasty consistency.
3. Apply Mortar: Using a trowel, spread a layer of mortar along the base and on the edges of the first brick/block you will lay. Ensure the mortar layer is thick enough to allow proper adhesion, about 1/2 inch.
4. Place the First Brick/Block: Carefully place the first brick or block onto the mortar, ensuring it’s level in all directions. Use a spirit level to check.
5. Continue Laying: Repeat the process, applying mortar to the previous brick/block and to the base, and ensuring each brick/block is level and aligned with the others. Use spacers (a stick, a tile) if needed to keep the mortar joints the same thickness (often 10mm).
6. Check for Level: Frequently check that the course is level. If one brick is higher than the rest, tap it lightly with the handle of your trowel to level it. Remove any excess mortar before it sets.

Step 3: Building Up the Walls

1. Stagger the Joints: To increase strength, stagger the vertical joints from one row to the next. Don’t line up vertical joints from row to row.
2. Continue Applying Mortar: Apply mortar on the top of the previous course, and the end of the new brick, just like you did for the base course.
3. Maintain Level and Alignment: Keep checking that each course is level and that the walls are growing vertically.
4. Build to Desired Height: Continue building up the walls until you reach your desired height.
5. Creating the Firebox: When you reach the point where you will create the firebox, stop and assess how the firebox and grate will fit in. Ensure enough space, and if you are using metal support angles, position them carefully. Use firebricks as you build the interior of the firebox for extra heat resistance.

Step 4: Installing the Grilling Grate and Other Features

1. Install Supports: If using support angles, install these carefully in a level manner. You can secure these into the mortar as it is setting. If not using support angles, you may be able to build in brick ledges to support the grate. Make sure your supports are positioned to support the grilling grate securely and at the correct height.
2. Place the Grilling Grate: Test fit your grilling grate to ensure it sits comfortably on the supports.
3. Add Finishing Touches: You can add features such as a side shelf, wood storage, or a chimney, depending on your design. Remember to always build for heat resistance.

Step 5: Curing the Mortar

1. Let it Cure: Allow the mortar to cure fully before using your barbecue. The time for curing depends on the type of mortar used. Usually 24-48 hours.
2. Keep it Damp: During the curing process, you can keep the mortar moist by gently spraying it with water, this aids in curing and prevents cracking.

Step 6: Curing the Barbecue and First Use

1. Gradual Heat Increase: Once the mortar is cured, start with a small fire to season the firebox. Build up the size of the fire gradually for several sessions, starting with a small fire, and gradually building up the size to burn off any moisture, chemicals, or other contaminants.
2. Check for Cracks: After the first burn, inspect for any cracks and address them as needed, this may involve adding more mortar.
3. Cook on! After a gradual curing of the brickwork, your barbeque is ready for its first meal.

Important Tips and Safety Considerations

• Wear Safety Gear: Always wear safety glasses and gloves when working with mortar, bricks, and power tools.
• Use Proper Ventilation: Ensure proper ventilation when grilling. Consider a chimney to help draw smoke away.
• Clear Flammable Materials: Keep flammable materials away from the barbecue while it is in use.
• Never Leave Unattended: Never leave a lit barbecue unattended, even for a moment.
• Handle Hot Surfaces Carefully: Use heat-resistant gloves and utensils when working with hot surfaces.
• Clean Regularly: Clean your barbecue regularly to prevent grease buildup and maintain hygiene.
• Consult Professionals: If you’re unsure about any part of the construction process, consult with a professional for advice or assistance.

Maintaining Your Outdoor Barbecue

Regular maintenance is key to ensuring your barbecue lasts for years to come:

• Clean After Each Use: Remove ash and grease after each use. A wire brush is ideal for this.
• Protect from Elements: Cover your barbecue during periods of inactivity, especially during winter.
• Inspect Regularly: Periodically inspect your barbecue for damage or wear and tear, addressing them promptly.

Conclusion

Building your own outdoor barbecue is a rewarding project that can bring years of enjoyment. With careful planning, patience, and attention to detail, you can create a unique outdoor cooking space that will be the heart of your backyard gatherings. From the satisfaction of building it yourself to the delicious meals you’ll share with loved ones, it’s an investment that will truly enhance your outdoor living experience. Remember to take your time, be meticulous in your work, and always prioritize safety. Happy grilling!