I made this grill just to cook kabobs on. Its inspired by a grill at a local middle eastern restaurant that cooks most if their food on a mesquite trough type BBQ grill. I thought this would be cool for parties and small cook outs.
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Step 1: Materials Needed
One section of black stove pipe.
( I got this from Menard's and it was relatively cheap. I used this because it is not galvanised metal, and is made for high heat. Don't use HVAC duct pipe because it's galvanized, and can give off dangerous fumes. Look for the pipe that is painted black.)
2 pieces expanded aluminum gutter guard.
(I got this from Rural King. There was a number of open packages, and they were willing to sell me just a few piece's for a few bucks.)
I made a stand from a keyboard sliding shelf from an old desk I had. I used the shelf as the base, and one of the sliding drawer arms as a stand.
Assorted screws, nuts, and bolts.
Step 2: Tools Needed
Ruler or tape measure
Large C clamps or other large clamp
Gloves (to protect your hands while cutting and bending metal)
A metal brake would be nice, but I used clamps and two lengths of hard wood.
Step 3: Bend the Metal to Form the Top of the Grill.
I don't have a brake to bend metal, so I clamped two pieces of hard wood to the top of my work space and clamped the stovepipe between the wood. The ends of the pipe have a seem on both parts that go together to form the pipe. I used this as a guide to make a straight bend by placing the seam along the inside edge of the wood brake. The wood was about 2" wide. I bent the metal, and used a hammer to crease the edge. I repeated this on the other side. This left me with two edges to rest the end of my skewers on.
I am using a 9" flat bamboo skewer, and I wanted to have a 6" gap. This gives me 1 1\2" on each side to rest the skewers. The gap was almost perfect once I finished with the brake.
Step 4: Air Gap
I used the expanded aluminum gutter guard to make an air gap on the bottom of the grill. This allows air circulation that will keep the coals hot. The metal was slightly bowed already. I marked it by laying it in the stove pipe and using a Sharpie to mark the length. I used metal sheers to cut it. I then cut a notch on both sides, about 1 1\2" from both ends, so I could fold the ends back. I did this to reinforce the ends so they wouldn't collapse under the weight of the charcoal. I used the hammer to crease the fold.
Step 5: The Base
Now, I know this isn't the best base in the world, but its what I came up with. I made it out of what I had laying around in the garage. This part I'm sure you all can improve on.
I wanted the base to be metal where it connected to the stove pipe, but small and portable. I also want to be able to put this grill on a table, or tailgate, and light it up.
I had a sliding key board shelf from an old desk I had in the garage. I used one of the sliding brackets, and the shelf to make the base. I put a self tapping metal screw in the sliding bracket while it was closed to lock it in the closed position. I then screwed the bracket to the middle of the shelf. I needed to place a strip of wood along the middle because the holes to screw the bracket to the board were not flush with the bottom of the bracket. I recommend pre-drilling these holes because the wood is narrow, and will split easily.
I then marked the stove pipe where I was going to drill holes. I did this by placing the pipe on the bracket and marking the holes with a Sharpie. I was afraid the stove pipe would collapse when I started to drill, so I set up a block of wood under it to brace the metal when I pushed on it. I clamped the pipe on and drilled the holes. I used some stainless nuts and bolts with a lock washer to hold it in place. In hind sight I would use both of the brackets, about 4" apart, to give the stove pipe more stability. Having just the one bracket is a little wobbly.
Step 6: Putting on the Ends
I used the left over pieces of expanded aluminum to make ends for the stove pipe. I used a Sharpie to draw the shape, and cut out about 1" larger all around. I folded it to fit in tight. I didn't screw these in, there just friction tight. Riveting them in place may be an option. Having them lose keeps the coals in, lets the air flow, and makes for easy cleaning of the ash.
Step 7: Time to Cook!
I started some coals in a chimney on a separate small grill, and placed the grill outside. (It was raining when I did this so I'm right outside my garage here.) I placed some foil on each side, just to make clean up easier. I put in the hot coals, making one even layer along the bottom on the grill. I then put on my Chinese BBQ Chicken Kabobs. (See my other instructable for the recipe.)
I'm using bamboo skewers, so I soaked them in water for 30 minutes before I made the kabobs. This will keep them from burning. My 9" skewers fit perfectly. 6" of chicken, with 1 1\2" on each end.
As I stated before, I made this to use with a flat 9" skewer. There is no grate to place the food on. Its directly over the coals. Because they're flat you can flip the skewers and your food won't roll around on them, burning on one side and staying raw on the other.
The Kabobs came out great! This is high heat, so watch you food. The kabobs are close to the coals so it chars quickly, which is what I was looking for.
I hope you like this instructable! Let me know what you think, or if you make your own. Please vote if you like it. Thanks!