I needed a large BBQ smoker for work,
I don't have a welder so have used rivets bolts.
Angle grinder, metal cut and grind disks
Metal Drill bits
Sanding stuff (i used a grinder flapper wheel)
High temp stove/BBQ paint
Step 1: Prep
First I sanded off the paint on the lid, I will sand the rest later (it's wet here)
Using a piece of string I marked off a quarter, then made a rectangle for the lid 40mm in.
Step 2: Cut Out the Lid
Using an angle grinder I cut out the lid, being careful at the corners. I then cleaned up the edges with sandpaper. Also, I got some free soy sauce with mine!
Step 3: Making the Lip
To stop the lid falling through I used two thin strips of stainless steel I had, but use what you have.
I cut the strips to length and riveted them on the inside of the barrel.
I found starting in the center and riveting out kept them flush.
Step 4: Add Hinges
I lined up the hinges and center punched and drilled two holes on each hinge at opposite corners. Then checking it swings properly and adjusting, drilled and riveted the rest.
Step 5: Handle
For the handle I just used an old stainless steel cupboard door handle I had and drilled through the lid.
Step 6: Making the Chimney
To make the chimney I used a turbo I had recently changed on my Landrover as it had places to bolt through. But I think a lot of exhaust parts would do the trick, see what your scrap man has.
I just cut the two pipes off, job done.
Step 7: Grill Rack and Chimney
For grill racks I used threaded bar.
I drilled two level holes just below the door level on each end, I then fed threaded bar through putting a nut inside and out on both sides. I tightened the two outside bolts first to put tension in to them, then used the inside nuts to lock them, this made the barrel much stronger. I left the bars long on one side to hang tools.
For the top rack I used a similar idea, but put them through the top bracket on the exhaust pipes as well, with a nut and bolt to secure each chimney through the second hole.
Step 8: Frame
I just made a simple frame. Using 4 legs secured using washers as shown, this means it will fold away. With a cross member at the top to hold the BBQ and halfway up the legs for support. Chains stop it opening too far and enables adjustment. This was just attached using self tapping bolts.
Step 9: Finishing
I sanded it and used stove spray paint to give a satin black finish.