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DIY BBQ Grill

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    Prepare the Area

    • 1). Level the area where you want to install the BBQ grill. Use the shovel to dig a square in the area where you plan to pour the concrete pad to a depth of approximately 10 inches. Use a plate soil compactor to pound the soil flat. Use the level and tape measure to check the initial uniformity of the hole.

    • 2). Cut the 2-inch by 4-inch boards into four pieces for the frame of your concrete pad. The lengths depend on the area you need and the geometrical shape you want for the pad -- square or rectangle. Place the boards into the hole in a square or rectangle shape, and use the level to check for uniformity. Further compact the soil if the boards are not level.

    • 3). Hammer in the 2-inch by 2-inch stakes every 24 inches around the outside of the frame to hold it in place. Place the stakes deep enough to be flush with the edges of the 2-inch by 4-inch boards.

    • 4). Mix the concrete in the wheelbarrow using the cement mix, sand and water; follow the manufacturer's instructions. Pour roughly 6 inches of concrete into the frame. Lay the wire mesh on the wet concrete and gently push it into the concrete about an inch. Pour more concrete until it reaches the top edge of the frame. Tap the outside edges of the frame gently to remove any air bubbles from the concrete.

    • 5). Level the concrete with the remaining 2-inch by 4-inch board. Drag the board across the wet concrete repeatedly until the surface appears smooth and level.

    • 6). Allow the concrete to dry. Consult the instructions of your chosen brand to calculate the drying time according to the climate conditions and mixing techniques used.

    Build the BBQ Grill

    • 1). Lay out the bricks in the pattern you want to use for your BBQ design. These instructions produce a rectangular design with a back wall, two side walls and an interior wall that divides the BBQ into a grill area and a preparation area. Use the BBQ grill as a guide for the required distance between the left side wall and the interior wall. The distance should be less than an inch between the grill and each wall.

    • 2). Calculate the total height you want for the BBQ structure. This depends on the height of the people who will use the grill. Take into account the ideal height for cutting items in the preparation area and manipulating the food on the grill. Most people prefer work areas a few inches above waist height.

    • 3). Mix the cement for the mortar to use with the bricks according to the directions on the bag.

    • 4). Spread the mortar for the first course of bricks according to the pattern designed earlier. Place the bricks on the mortar and use the level to ensure that they are laid flush. Connect the outer walls and interior wall to the back wall with metal ties for added stability.

    • 5). Lay the extra courses of bricks beginning at the corners. Stagger the courses by half a brick to alternate the placement of the vertical joints to ensure the structural integrity of the project. Use the level to verify that the corners are vertically straight, and the finished structure will be square.

    • 6). Lay five courses of the structure. Place a board between the corners and use the level to verify that the structure is level.

    • 7). Lay two more courses and create a shelf on the seventh course by turning the bricks of the left and inner walls sideways. This creates an outer edge of half a brick and inner protrusions to support the metal tray for the charcoal or wood on the left side and the preparation area on the right side. Lay three more courses and repeat the process to create supports for the BBQ grill. The course numbers for the supports depend on the overall height desired for the structure. Add or subtract the number of courses necessary to achieve the desired height, but do not space the supports more than three courses apart.

    • 8). Cement a paving slab to the right side of the structure to create a preparation area for your BBQ.

    • 9). Lay one or two more courses around the grill area to complete the structure. Run a length of flexible pipe along the joints to clean up the mortar and give the BBQ grill a professional finish. Allow the mortar to dry for the indicated amount of time before attempting to use the grill. Slide the metal tray and grill into the designated areas after the mortar is dry.

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