There is some cutting, drilling and bending of metal involved, but no welding. It took me about an afternoon to finish.
(The picture shows the first BBQ I made, because the second one hasn't been used yet.)
Step 1: Gather Your Raw Materials
You'll want the sink(s) to be more or less in the middle; a bit off center is acceptable, you can adjust for that.
This is a suitable countertop. It's on the thin side but it'll do. These are very easy and cheap to acquire in the Netherlands.
You will need:
- steel countertop with two sinks
- two planks
- screws to attach the planks
- nuts and bolts (stainless steel is best)
- grid or mesh for below the coals, can be low-quality
- griddle for the food to be grilled on, needs to be foodsafe; stainless or chromed if you can get it
- gloves (sharp edges!), ear and eye protection
- saw for metal, or an angle grinder
- pliers or wrenches for bending
- wire cutters for the grid or mesh
- paint scraper
Step 2: Remove Everything That's Not Steel
Step 3: Remove the Drain Materials, Too
Step 4: Time to Cut the Edges, and Fold the Countertop
Take out your angle grinder (or a saw) and cut the folded edges on either side, so the countertop will fold easily. Allow for the metal on both sides of the cut to overlap (see third picture).
Fold both ends of the countertop upwards (with the countertop lying upside down). It's easier than it looks. I did it by hand and I'm no Wonderwoman. I just stood on it, pressing a piece of wood down with my feet, and pulled the end upwards with both hands. Easy-peasy.
Step 5: Now We Add Some Stability
Get two pieces of lumber that are rougly 10 or 20 cm longer than what will be the top of the BBQ. Make sure they are the same length. Width and thickness do not matter much.
Use screws to attach them between the 'legs' of the BBQ, connecting them. Do not try to make the legs parallel and at a 90º angle to the top: a trapezium shape has a lot more rigidity than a rectangle. That is why the planks need to be longer than the current length of the top of the BBQ.
Step 6: Even More Stability
Now bend the legs into their desired position (so the whole construction is symmetrical) and drill a hole in those overlapping corners. Connect the two layers of steel with a stainless steel nut and bolt on each corner. Hammer down the nasty sharp edges at each corner.
Step 7: Finishing Touches
Finally, you'll need some foodsafe griddles to put the food on. Old oven griddles work really well. It's nice if you can think of a way to make one of them adjustable so you can grill higher above the fire.
Now fire it up! Heat your brand new BBQ thorougly without grilling anything once, before you start using it, as there may be dangerous fumes from leftover glue and whatnot.
There you have it. Your very own WTFBBQ. Invite some friends, get some tasty food, and enjoy!