How to Convert a Metal Barrel Into a Grill

An old 55-gallon metal barrel is the ideal raw material from which to create a homemade outdoor grill. The size, shape and thickness of the metal seem almost designed for recycling purposes; the resulting grill is efficient, practical and almost entirely free if you use recycled materials. Producing a simple grill requires no previous engineering or fabrication skills although it is important to remember that whenever cutting tools are used, suitable safety precautions should be taken.

55-gallon steel drum
Plumb line
Strong gloves
Goggles
Angle grinder
Newspaper
Scrap wood
Wire brush
Steel mesh sheeting
Tape measure

Instructions

- 1
  Place a 55-gallon drum upright on a horizontal surface. Draw a line from one side of the barrel top to the other side, passing through the center. The line should divide the top into two equal semi-circles.
- 2
  Use a plumb line to extend the line across the top into two vertical lines, one down each side of the barrel. Mark the path of each vertical line to the base of the barrel, then turn it upside down and join the vertical lines to create a final line bisecting the base.
- 3
  Don strong gloves and safety goggles. Cut along the lines with an angle grinder fitted with a metal cutting disk. Examine the two half barrels, and select the best looking half. Discard the other section. Tidy the cut edges, using a hand file, to remove burrs, sharp edges and any other irregularities.
- 4
  Place the half barrel flat on a non-flammable surface such as bare dirt. Fill it with newspaper, small sticks and scrap wood. Set fire to the paper and allow the fire to burn off any contaminants and all external traces of dirt and paint. Leave the barrel to cool, and then empty it and clean it all over with a wire brush.
- 5
  Rest old bricks in the base of the barrel to form a "brick floor" that will protect the metal base from excessive heat.
- 6
  Measure the internal width of the barrel about two inches below the lip of the barrel, then measure the internal length. Mark the width and length onto a sheet of rigid steel mesh, and cut it to shape.
- 7
  Place the steel mesh in the barrel, forming a shelf that rests slightly below the lip. This forms the cooking shelf of the grill.

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