Introduction: BBQ Conversion to Gas
I built a charcoal BBQ some years ago and I hate how long it takes to fire up. I looked at new gas grills and thought I could just make one myself for a lot less. Here is the basics of how to convert one yourself. This could be applied to any charcoal grill, with a round fire ring a Webber could be converted as well.
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Step 1: Parts Needed
For Natural Gas:
1) 3/8 NG hose and a needle valve to adjust the flame size. I use brass 45deg flair fitting for the hose ends and the attachments at the BBQ and house.
2) Fire ring/bar. This is the distribution system that is below the grill for your gas. If you have the ability to weld and make rings you can make your own using a 1/2 weldable (not cast iron) coupler in the center, 5/8 thin wall tubing for the ring and drilling 3/32 holes every 1 1/2". The ring should 1/2 - 1/3 the size of your BBQ container diameter.
Stainless steel will prolong the life of the ring especially during the winter when you forget to cover your BBQ in the first rain. I've heard of people using copper too.
3) BBQ Fittings: A 1/2 NPT brass bulkhead coupler and 1 1/8 lock nut, or a 1/2 weldable steel coupler, Brass1/2 to 1/4 reducer, 1/4 street 90, neddle valve, 45 deg flare (for attaching the hose to)(not used in this build), brass 1/2 NPT nipple (to attach the the ring to the coupler welded to the container)(not used in this build).
4) House Fittings: all brass; 3/4 to 3/8 reducer, 3/8 street 90, 3/8 nipple, 3/8 ball valve, 3/8 to 45 deg flare for attaching hose to BBQ.
For Propane:
1) Regulator/hose 1-30 PSI (not a BBQ regulator, too small) and a needle valve to adjust the flame size. I use brass 45deg flair fitting for the hose ends and the attachment at the BBQ. BBQ propane tank. You will need a venturi if the propane flame is too smoky.
Alt.: Home Depot sells replacement BBQ parts. Buy the reg, hose, burner and install in your charcoal grill.
I've put together an affordable kit of the basic plumbing supplies you'll need to build a fire pit. This kit could be used to build a BBQ as well.
I offer several sizes of rings, stainless upgrades and fully auto systems for high end remote controlled fire pits.
Fire Pit Kit link
Step 2: Make a Hole
1) The fire ring/bar should be 4-8 from the grill. Closer will give you hot spots and farther will even out the heat. I chose 5 so I could have hot spots for the meat and veggies could cook slower on the sides.
2) Locate and mark the hole for the bulkhead fitting on the BBQ, then center punch. Make sure you are center punching with a hard object backing up the other side. if you don't your mark will be too light and you risk just making a big dent. Now using a hole saw on a drill, make a 1 1/8 hole. if you find the bit wandering off center go back and make a better center punch. Stainless steel is very hard and lots of pressure is need to get it started.
Step 3: Add the Plumbing
For this build I use a brass Bulkhead fitting & set nut. It fits snug in the hole and needed no additional sealant or welding. Use a wrench to make sure it's tight. Now thread the fire ring on one side and the 1/2 to 1/4 reducer, 1/4 street 90, needle valve, and 45 deg flare on the other. I used Teflon tape to seal.
Alternates methods of plumbing the gas though the container for thicker materials:
Bolt on flange - great for thick material. Make sure to use a high temp silicon sealer to make sure there are no leaks. see attached photo
Weldable couple r- The best solution, but you must be able to weld.
Now attach the hose/regulator using the 45 deg flare fitting on the end of your hose.
Step 4: Natural Gas Hook Up
When I built my house I made sure to leave a t so I could hook up "other things" later.
!st shut down your gas. Next I removed the plug and replaced it with a ball valve and a 3/8 45 deg flare fitting to attach to the hose.
Now hook up the hose.
Step 5: Propane Hookup
Propane (not used in this build)
Follow the instructions in steps 1-3. In step 3 complete the connection of the bulk head fitting to the fire ring/bar, then attach the Venturi shown below to the bulkhead fitting. A 1/2 F npt to 45 deg flare threads on to the venturi to attach the hose to. The 30 psi Regulator has the needle valve attached to it, but this could also be placed at the BBQ for easy reach to adjust the flame size.
The venturi introduces air to the gas and takes the soot away. The one I sell has an adjustment nut to fine tune to your BBQ.
I used Teflon tape to seal all the NPT fittings.
Step 6: Time to Cook
Zolie suggested we get out the fire hat in case we didn't do it right.
This is a match light set up and a long BBQ lighter is a must. It worked pretty good and is much easier then lighting briquet's.
I like some smoke in my food so I lined the bottom of the grill with several pieces of apple wood. You have to make sure it's not so close to the flame that it burns, but close enough to slowly smoke away. I also have an abundance of thyme that I spread over the grill top that gives me plenty of smoke and flavor.
Additions I might add are:
Push button lighter
thin sheet metal over the flame to spread out the heat more.
Meat to eat.
Have fun
Link to my Fire kit site.
http://www.formandreform.com/wordpress/?page_id=2568

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28 Comments
7 years ago
I went to Home Depot to get the propane BBQ parts, but the replacement burner has a slip fitting for the needle valve to fit into. Is there some sort of part to adapt from 3/8" flare to the slip fitting?
12 years ago on Introduction
Great instructable Jon! I completed mine, a propane setup. I'm having a problem, the flame isn't getting hot enough. What should be a 20 minute cook time is taking more like 45. The flame doesn't get very high, and acts as if it's trying to go out. Every few seconds it makes a "poof '' sound and the flame goes down and then starts up. What did I do wrong?
Reply 12 years ago on Introduction
send me a picture
12 years ago on Introduction
It takes 20 minutes from deciding to have a BBQ to having the coals ready...and that includes getting the beer out of the fridge...how can that be too long?
Reply 12 years ago on Introduction
I agree with you. It doesn't take that long to have a barbecue ready and gas is getting more and more expensive. I can buy a ton of bits of high density, well dried french oak for 25€ from a flooring factory nearby. A 45 kg propane tank is selling at 76€ and rising. Some people can't get firewood that cheap, some can get propane for a lot less. I'll stick with firewood. (That doesn't mean the author hasn't done a good work.)
Reply 12 years ago on Introduction
I agree the author has done good work. what i hear a lot of the time is that it takes a really long time to get a charcoal bbq ready to cook on, and it is just not true in my expereince
Reply 12 years ago on Introduction
Plus the time to buy the charcoal. Still too long when you have 4 year old who wants to eat now!
Reply 12 years ago on Introduction
Agreed. Looks like he needs one of these: http://www.google.com/search?aq=0&oq=charcoal+ch&sourceid=chrome&ie=UTF-8&q=charcoal+chimney
12 years ago on Introduction
mm gas flavoure'd meat. mm. please sir, can i have some more?
Reply 12 years ago on Introduction
I don't understand what your talking about I smoke my meat with this grill
12 years ago on Introduction
Here in australia we have kits for this for about $99Au You get everything to convert your Lpg bbq to a natural gas set up except for the jets they have to be specialy ordered for the particular bbq from the manufacturer or you can try to make your jets bigger with a drill but chances are you will make them to big - that is one difference in nat gas and Lp gas bbq's the jet size But you still need a licensed plumber to install it and generaly people do it to bbq's that look like they will last more then a week without the rust flavours
12 years ago on Introduction
Just wondering on the teflon thread tape you used: is it the standard white for water, or the colored tape formulated for use with propane/NG? I've read that the white tape will breakdown over time with exposure to gas. I think you would have to check for that with soapy water. Have you noticed any degradation of the tape? Other than that question, I think it's a fantastic build. BTW, you've got a great apprentice there! : )
Reply 12 years ago on Introduction
http://en.wikipedia.org/wiki/Thread_seal_tape
for more info.
I use pink, yellow and white. White is thinner.
I like to use a small bit of pipe dope along with the tape.
12 years ago on Introduction
its probably a bad idea to connect things to mains gas, and in the UK is illegal unless you have a gas safe listing. propane is a much better idea IMHO
Reply 12 years ago on Introduction
Not a problem here. Making things is sometimes dangerous, be smart and use common sense. NG has a lot of benefits over propane and I like not having to get propane all the time.
12 years ago on Introduction
Correct me if I'm wrong, but did I see in the before/after pictures that you simply removed the MAIN SHUTOFF VALVE internals to connect your branch tee to???!!! What happens if you ever need to open your system for any reason.. i.e. repairing a ruptured/broken pipe et al? I hope your home is well insured and that your local gas provider never sees that.
Reply 12 years ago on Introduction
No I did not remove my shutoff valve. I did add a shut off to this project so I can safely turn it off at the house.
12 years ago on Introduction
You need to put some air ( venturi) in to your Natural Gas burner. The flame should be blue like your gas stove top not yellow. There is no heat in yellow flames. Plus Natural Gas and LPG jets are different. Keep up the good work.
12 years ago on Introduction
great idea but i don't understand why you would want to cook on a bbq with gas? you might as well put a grill over your gas hob. it's supposed to be all about the smoke, poking coals and the hot and cold spots!
Reply 12 years ago on Introduction
Sorry missed a step. I added above in step 5 I like some smoke in my food so I lined the bottom of the grill with several pieces of apple wood. You have to make sure it's not so close to the flame that it burns, but close enough to slowly smoke away. I also have an abundance of thyme that I spread over the grill top that gives me plenty of smoke and flavor.