Grill design

I want to make a charcoal grill, about 3'x3' or 3'x4', open top. Its intended for the occasional big cookout, mostly for slow cooking foods like chicken and such.

The cooking and charcoal grills will be made of 3/16 or 1/4" CRS rod. My question is, how deep should I make the grill? I think the cooking grill should be 1/2" or so under the lip, but I'm not sure how much space to put between the bottom and the charcoal, and the charcoal grid and food grill. Also how much airhole space will it need under the charcoal?

This will be a simple flatbottom grill, with removable legs. The cooking grills will be multi piece, 3 or 4 grids.

Thanks for any thoughts (in writing!) :) John

Reply to
John T
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My cooking grates are flush with the top edge of the box. Makes life easier getting big things on and off. The charcoal grates are adjustable from about a foot below the cooking grates to a few inches below them. I have a removable ash pan at the bottom of the box. The charcoal grates are about

1.5" above the bottom of the pan at their lowest point.

My cooking grates are 7 1/2" wide by about 18" deep . My fire grates, are about 10" wide by 16" deep. You might considering designing around replacement grates from a major company like Weber for you cooking grates. I think Weber's are 17 3/4". That is what I designed a clone of my barbecue for a friend around.

If you don't have a top, I don't think air will be a problem. If you do, it doesn't take much area. There is enough area in the cracks between the door and the front of my unit, and in the space between the top of the ash pan and the front of the unit to provide adequate air even with the top down in my barbecue. Total area in the adjustable vent holes in the top is maybe 8 sq. in.

My cooking grates and charcoal grates were cut out of 1/4" steel plate and work fine. I think 3/16" round stock may be too light unless it is well supported. The 1/4" stock will certainly last longer in the charcoal grate.

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