Making a grill out of aluminum.

Step 1: Grill Plans

Working on A+ Cad I drew out the sides of the grill with the handles. For the longer side, the dimensions were 24&3/4 x 2 inches with an angle of 55 degrees on the corners. The shorter sides were 15&3/4 x 2 inches with the same angle on the corners. Before I did anything, I cut out cardboard templates to see how it would fit.

The handles from inside to inside are 1 5/8 inches out and 4 inches wide. For the corners on the handles the angles on the outside and inside are 90 degrees with a slight curve on them. There is a 5 inch length from the corner to the handles on each side. For the part of the handle that you hold, it is 3/4 inches wide.

Step 2: Cutting the Bottom of the Grill and Sides

The dimensions for the base was 22&1/4 x13&1/4 inches aluminum at 1/4 inches thick. Setting the pieces of aluminum on the plasma cutter, I pulled up my files and made sure everything was on the right coordinates. Cutting the aluminum out to exact dimensions, now you are ready to sand the edges and make the sides smooth.

Step 3: Sanding the Edges/ Tacking Together

Getting 100 grit sand paper and an orbital sander, sand the edges for smoothness and for better welding. Eyeballing it and having someone else hold your sides together, begin tacking. Make sure to not have one side up higher than the other.

Step 4: Welding the Main Frame Together/ Finished Product

After getting it tacked together, start cleaning the metal with a wire brush. This makes your welds flow better and look better. Only weld the back side of the grill so the front side has metal seams that are exact and clean. However, if you do weld the front side, grind the welds down so they are smooth and sand the seams with 100 grit. This makes for a nice smooth finished grill to cook on.