How to Build a Grill Out of a 55 Gallon Drum

One of American’s favorite hobbies is grilling. So it only makes sense that as with everything else, bigger is better. You can make your own grill using a 55 gallon barrel drum which is big enough to handle any rack of ribs that you have to throw on it. However, in order to complete this project you should have some experience using power tools such as a reciprocating saw, welder and drill. You should also have about 6 hours of spare time in order to complete this project.

What You Will Need to Build Your Grill

You should gather all of your materials, supplies and tools prior to starting the construction of your new 55 barrel grill. This will save you time searching for materials while working. You will also have a clear idea of the items you will need to purchase at one time without having to travel to your local hardware store multiple times. For this project you will need the following items:

A 55 Gallon Drum Barrel that is in good condition and free of any rust or other cuts and holes. Since this grill will be used for preparing food it is best to either purchase a new barrel that has never been used or use a barrel that was previously used to store consumable items such as cooking oil. Never use a barrel that was used to store toxic materials as they may get into the actual structure of the barrel and be released when the barrel heats up.
Reciprocating Saw or Sawzall that has a blade designed for cutting through metal.
Grinder that can be used for smoothing out any rough edges on the metal from cutting.
A metal mesh and Bars that can be used as a grilling grate or grilling rack for cooking.
A set of hinges and a handle to form the grill lid.
Welder and necessary supplies
Metal bars for constructing the legs and stand of the grill.
Safety equipment such as safety glasses, welding mask, gloves and other safety supplies as needed.

Constructing Your 55 Gallon Barrel Grill

Step 1. Measure out and mark off one quarter of your metal barrel that will be used for the lid of the grill. Start in the center of what will be the top of the grill and measure out to the center of the side. Use masking tape or a marker to make the lines where you will cut the opening.

Step 2. Cut along the area you marked using your reciprocating saw or sawzall. Make sure that you make clean, even cuts as this will help when lining everything up.

Step 3. Use your grinder to sand down any rough edges that are left behind after cutting.
Step 4. You will now need to start constructing the inside of your grilling surface. To do this you will need to weld bars at each end of the 55 gallon barrel drum. You will also need to weld two support bars in the middle which will be used for easier grate removal when needed. Any rough edges should be welded as well to prevent anyone who uses the grill from getting injured on them.

Step 5. Attach your hinges to the top of the lid on the grill and door. Attach the handle to the lid in the center of the bottom in a pattern that will make it easy to open and close the lid for whoever will be using the grill.

Step 6. Constructing your base is fairly simple as long as you make sure that the four legs are even and sturdy. Depending on what type of materials you will be using for your base you will want to make sure that you weld them in a fashion in which they will be able to support the weight of the grill. Anchor the bottom of the legs with a piece of metal mesh material or another horizontal style bar running from one leg to the other along the bottom of the grill. This will help to create a more stable construction for the grill.

Step 7. You can attach a few wooden boards along the front bottom ledge of the grill to act as a small table for grilling convenience.

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