How To Build A DIY Charcoal Grill? 3 Ultimate Ideas

Are you looking for ways to DIY a charcoal grill that can provide your family with delicious meals without incurring any additional costs or waiting times? 

You may be interested in understanding the fundamentals of how a charcoal grill functions.

Doing so will give you a better idea of the necessary components required to build a basic yet effective charcoal grill all on your own. 

Know what materials you will need and how to construct a charcoal grill that meets your specific grilling needs.

TWO MUST-HAVE PARTS FOR ANY CHARCOAL GRILL

In the market nowadays, you can find many types of charcoal grills, each having its own unique features and design. Our DIY charcoal grill ideas are basic plans for making a simple charcoal grill out of materials that are easy to find.

We pay attention to the charcoal grill’s most important parts: the base and the grate.

The base/ bowl

Back to the must-have parts for any charcoal grill. First, we have a base. This is an important part of starting a charcoal grill. 

The base of a charcoal grill typically refers to the bottom and the walls of the grill.

It gives the grill a stable base that lets it hold the charcoal and support the cooking grate. 

If the grill doesn’t have a strong base, it might not be able to keep the same temperature or hold the weight of the food being cooked. For instance, a metal base that is thicker will hold and spread heat more evenly than one that is thinner

The base of a charcoal grill is typically made from a heat-resistant material such as metal or ceramic.

The grate

The grate, on the other hand, is the surface on which the food is cooked.

A grid-patterned metal or wire grate rests on top of the base to provide a sturdy cooking surface.

The grid layout of the grate stabilizes food and allows ventilation and direct flame contact when needed. This design creates classic grill marks and lets fat and oils drip away, blocking flare-ups and carcinogenic char.

It needs to be strong and durable enough to hold the weight of the food and withstand the heat of the charcoal. 

The size and shape of the grate will depend on the size and shape of the base.

Electric barbecues may employ coated non-stick grates, which are unsuited for charcoal grilling’s intense heat.

The base and the grate work together to create the perfect environment for grilling with charcoal.

The charcoal is placed at the base and ignited, creating heat and smoke that rises up through the grate to cook the food. 

Noting that the base and grate of a charcoal grill are unique to charcoal grills and are not interchangeable with other types of grills like gas or electric grills.

Charcoal grilling is a different way to cook. The charcoal grill depends on the heat and smoke that comes from burning wood and charcoal.

Charcoal grill grates are built to resist strong coal heat. Gas grills feature thinner grates since the heat source is more controllable and mild.

Side components

These ideas may not include other components like lids, vents, or ash catchers, which are more advanced features.

The venting system of the grill, which can be adjusted to control the flow of air and heat, is also an important part of the charcoal grill.

This is because making these parts takes more time, materials, and skill, and they may not be needed for a simple charcoal grill. 

Additionally, some of these components may not be compatible with the materials used in DIY ideas, such as a lid for a metal trash can grill.

But if someone is more skilled and has the right tools, they could add these parts to their do-it-yourself charcoal grill to make it work better. 

What Can Be Used As Base

When it comes to creating a DIY charcoal grill, there are several materials that can be used for the base, depending on the design and the resources available. Some common materials for the base include:

Bricks or cinder blocks

These can be stacked to form a sturdy base that can withstand high temperatures. They can also be arranged in various patterns to create a unique design.

Metal drums or barrels

These can be cut in half lengthwise to create a base and a lid. The base can be fitted with legs and a grate to hold the charcoal.

Terra cotta pots

Large terra cotta pots can be stacked on top of each other to create a base. The pots can be sealed together with high-temperature silicone sealant.

Steel plates

Large steel plates can be welded together to form a box-like base. The base can be fitted with legs and a grate to hold the charcoal.

Wooden pallets

These can be stacked to form a base. However, it’s important to use untreated wood to avoid harmful chemicals getting into the food.

No matter what kind of material is used for the base, it needs to be stable and safe. The base must also be able to handle the high heat from the charcoal without melting, warping, or catching fire.

Choosing The Grill Grates

The general idea behind the materials for a grate in a DIY charcoal grill is to use something that is heat-resistant and has gaps or openings to allow the heat and smoke to circulate around the food being cooked. 

This can include traditional grill grates made of metal, such as cast iron or stainless steel, or even non-traditional materials like expanded metal, wire mesh, or even rebar. Or with a grate, you can raise or lower to different heights. It can give you more flexibility in cooing choices and over the cooking process.

The key is to make sure that the grate is strong enough to hold the weight of the food and tough enough to stand up to the high heat that comes from the charcoal.

These are just general steps for each idea, and may vary based on the specific materials and tools you use.

It’s important to always follow proper safety precautions when using a welding torch or working with fire. Got some quick tips for picking the right grate: 

Size: Make sure it sits well within the brick boundaries. You don’t want it too small or hanging over the edges.

Style

• Flat or Raised Edges: Flat is standard, but raised edges can help keep food from falling off.
• Handles: Helpful for lifting and cleaning, but make sure they don’t interfere with the lid if you have one.

Pattern

• Grid: Good for smaller items like veggies and shrimp.
• Bars: Better for larger cuts of meat, as they offer more surface area for searing.

3 DIY CHARCOAL GRILL IDEAS

There are many approaches to creating a DIY charcoal grill, from building a brick pit from scratch, or using recycled materials like old oil drums,…

Many things in your house or backyard can become ingredients for a charcoal grill that can give you perfect grilling results.

But in this article, we’ll focus on the three easiest and most popular ways to make your own charcoal grill, even though there may be different ways to do these things.

By the end of this guide, you’ll have the knowledge and inspiration you need to create your very own DIY charcoal grill.

Creating a Brick Barbecue Pit

Brick barbecue pits are great for larger gatherings and can be customized to fit your specific needs.

This method takes more work, but it can give you a permanent and beautiful addition to your backyard. A brick charcoal grill will last you much longer than the usual steel designs sold in stores.

How to do

Step 1: Mark the Area

• Pick Your Spot: When I chose to create a brick BBQ pit, location was key. For safety, I chose a site 12 feet from my house. Choose a location 10-12′ away from flammable stuff and buildings. 
• Level the Ground: Make sure you’re starting on a flat surface. Leveling the ground was difficult but worthwhile. 
• Plan the Size: Lay your grill grate on the ground to visualize the dimensions. Mark them down.

When I chose to create a brick BBQ pit, location was key. For safety, I chose a site 12 feet from my house.

Step 2: Prepare the Ingredients

• Choose Material: Pick bricks, stone, or concrete that match your aesthetic and budget. I went for a mix of red bricks and natural stone, aiming for a rustic look that complements my garden.
• Mix Mortar: I blend 3 buckets of sand to 1 of cement on a tarp. Then I add water until smooth. Mixing mortar was very therapeutic. Like cooking, but for constructing! 

Step 3: Build the Structure

• Lay the Base: On soft ground, I dig a trench and set down concrete blocks. I kept checking the level after every few bricks laid; precision was my mantra.
• Start Building: Use a trowel and level to construct a 3-sided box—21″ wide by 30″ high.
• Internal Supports: After 6-7 brick layers, lay bricks perpendicularly as supports for your trays.

Step 4: Add Finishing Touches

• Rack & Pan: Drill holes for heavy-duty pins or use brick supports to place your grill rack and charcoal tray. Drilling the holes for the grill rack was tricky, but seeing the heavy-duty pins fit perfectly was rewarding because of the superiror grill you are going to have. 
• External Casing: Once the mortar sets, add an extra layer or render for durability and see the rough construction become a streamlined BBQ pit 

Step 5: Ready for grilling

Once the charcoal is hot, and make sure they reach high heat  so that they can grill your food to perfection. Then add the grill grate on top of the barrel and start cooking your food. Grilling on a pit that I built with my own hands made the food taste even better. 

Utilizing a Terracotta Pot

Most gardening and hardware stores sell terracotta pots, so this is an easy and convenient option. I searched the garden area of my local supermarket for the right terracotta pot with many sizes possible. 

This method is great for smaller gatherings or those with limited outdoor space.

How to do

1. Find a large terracotta pot that can accommodate the amount of food you want to grill. 
2. Cut out a section of the bottom for air flow using a power saw or a jigsaw. Cutting out the bottom section for airflow was the most challenging part. I had to borrow a power saw from a friend. 
3. Add metal legs to the base to prop it up, ensuring that it’s stable and level.
4. Place a metal grill grate on top of the pot, making sure it’s securely in place. Putting the metal grating on top was straightforward, but securing it needed some tweaks.
5. When I positioned it properly on the pot, I knew my small grill was ready. Add charcoal to the pot and light it up, making sure to follow the safety guidelines when using a fire.
6. Once the charcoal is hot, and usually it takes about 15-20 minutes for a charcoal to be ready. Then add the food to the grill grate and start cooking.

Note: Cutting out a section of the bottom can be challenging and may require specialized tools. Care should be taken to ensure that the pot is sturdy and will not tip over during use.

Using a Metal Barrel or Drum

Metal barrels or drums are readily available at recycling centers and junkyards, making this option popular. They carry and store liquids and may be used for DIY projects. Steel barrels are sturdy and heat-resistant, making them ideal for grilling.

How to do

1. Find a clean, non-hazardous metal barrel or drum. Because barrels were formerly used to contain hazardous items, they can release toxic gases when burnt. It’s important for you to pick a barrel that held non-toxic things.
2. Cut a grill grate from the top using a power saw or jigsaw. For clean cuts and your own safety, use these instruments with care. Wear gloves, ear protection, and eyewear to prevent metal shards, noise, and harm.
3. Welding joins metal parts. Add legs and a handle to the base using a welding torch for stability and safety. It takes expertise and accuracy to stabilize the grill.
4. Place the charcoal in the base and light it up. Use lump charcoal or briquettes. They should optimize ventilation and heat dispersion.Following fire safety rules, particularly when your grill lighting in heavy winds.
5. Once the charcoal is hot, add the grill grate on top of the barrel and start cooking your food. The food-grade metal grating should fit firmly on the barrel.  It should be at the right height for grilling, with enough space between the charcoal and food to regulate heat.

Note: Beginners may find welding torches intimidating, so they should get guidance or expertise. Cutting the top may be risky, so use safety gear.

CONCLUSION

Overall, each DIY charcoal grill option has its own unique benefits and challenges.

It’s important to consider factors like the size of your outdoor space, the number of people you will be cooking for, and your level of DIY experience when choosing a method to follow. Some people make use of outdoor space and enjoy grilling on a wood deck but with careful attention.

Regardless of which option you choose, be sure to follow proper safety guidelines and use high-quality materials for the best results.