Inspired by the Vesto Stove, I set out to take some garbage and make my own high efficiency barbeque.
2 empy paint cans of differing size
Handfull of rivets
Full drill bit index
Masking tape, 2"
Pen or Pencil
Flatt head screw
Vice-Grip or Channel locks or Line-man pliers
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Step 1: Find 2 Paint Cans
You will want the outer can to be large enough to provide a decent cooking surface, with the inner can being only a bit smaller. The intent is to have an air chamber that will pre-heat the incoming air to increase efficiency of fire.
Step 2: Drill Vent Holes
You will now be making the template for the air holes.
A. Wrap tape at the top of outer can, and at bottom of inner can. Two layers may be necessary if there is writing underneath tape. Then intent is to have the air move as far as possible inside of chamber, so it would be counter-productive to have holes at same level.
B. Draw a diamond or lattice patter in tape. This will help give you a regular pattern when drilling the holes. Make pattern large enough to retain structural integrity of can.
C. Attach lid and tape in place. (2nd Image)
D. Drill holes.
I used a 6.5mm drill for the holes of both cans and used the same pattern on both cans as well. You may want to use larger, I have not yet tested this and may enlarge my holes as well.
I found that when drilling, I could minimise the jaggies if I slowed the drill before pulling back out of the hole. Its nearly impossible to elimate jaggies, so beware of being pricked.
You could punch the holes instead of drilling, but this would cause extensive deformation of the can.
E. Remove tape after all the holes have been drilled. Remove tape with a waving motion to reduece breakage - making the process easier.
F. Lastly, vacuum all the shavings so you don't track them all over the house. A note: make sure you have a good bag in your vac. If not, you will most certainly cause extensive damage to your vacuum.
Step 3: Mark the Top
You need to mount the smaller can to the lid of the larger can.
A. Run tape along the perimiter of lid.
B. Place smaller can in center of lid and trace around it.
C. Draw a smaller circle, about a thumb's width or an inch smaller than traced circle.
D. Draw connecting lines about a thumbs widht apart.
Step 4: Punch and Cut the Top
A. Punch holes along smaller circle where the lines intersect.
B. Using a large flat-head screwdriver, punch a line between these holes. Go all around lid.
C. The last few sections will be more easily done with tin-snips.
D. Cut along connecting lines with tin snips
E. Bend tabs down.
The lid should fit snugly over small can.
Step 5: Mount Lid to Can
A. Flatten lid to can - tapping with hammer will help. (4th image, not 3rd image)
B. Bend tabs to fit snugly to can.
C. Drill a hole for rivet through a tab and rivet. Repeat with tab on oposite side of can. Repeat wth tabs half-way between riveted tabs. Continue untill all tabs are rivited. You will want to fit each tab before drilling.
When drilling hole, press lid onto can, so it doesn't slip out of place. See 5th image.
Step 6: Final Assembly
Place inner can into outer can and snug the lid on.
Before you cook food on this bad boy, you will need to fire it up and burn off all the paint and other chemicals that my be on cans. You would be best to repeat a few times.