I want to build a 55 gallon grill and i'm curious if anyone has any plans or link for building one. I am sick of the ones you buy in a store. I always end up modifying them. Any assistance would be great.

I've been wanting to do that for a long time, too. Seems pretty straightforward in terms of building one. Chop in half, weld/bolt on some hinges, weld on a vent, legs, etc. Post pics if you end up doing it. :thumbup

Edit: Here's an even better idea than chopping in half.

http://i287.photobucket.com/albums/ll127/Mary1218_photos/Smoker_6.jpg

http://www.supermotors.net/getfile/503330/fullsize/bbq-kabobs.jpg

I have made 2. This one is the second, I didn't like the first because I cut it in half. I had the barrel welded to a rack with wheels to make it easier to move around. For the grill I used a shopping cart bottom cut to fit in 2 pieces so I can added or adjust the wood without having to lift the whole grill. The grill is supported by long bolts through the sides. Drilled holes in the bottom for air.

I was talking to the welding supervisor when I was an apprentice about building a grill for camping and he mentioned the fact that you can only use a certain type of materiel because steel gives off poison gasses when heated. I can't remember the stainless # he mentioned, but I believe it is the same material that is used for kitchen appliances.

Something you may want to consider

Are you sure you're not thinking of galvanized steel? I've never heard of steel alone giving off poisonous gasses.

Are you sure you're not thinking of galvanized steel? I've never heard of steel alone giving off poisonous gasses.

Yes, just plain steel. I was unloading a truck when I was an apprentice and a sheet of 2" plate had a sticker on it that described all the dangers associated with steel and the precautions to take while torching and welding steel. Now I never wore a respirator in the shop unless I was doing a lot of welding or grinding rust off a beam, and I have no problems and one shop I was in had the smoke so thick you could cut it with a knife and I was there for 8 years. That's not to say that I didn't suffer ill effects and will die prematurely as a result. I did, however, have nights when my lungs hurt so bad I was almost in tears, especially when I was smoking. So because I am aware of the potential, I would only use something that is recommended for such a purpose.

Thanks for the insight. i will look into all the option. as far as the steel putting off poison gases i would think it would come from the stuff the put on the bare metal to prevent rust. i would burn mine really hot for about 8hrs to get any toxins off the metal.

Use a 55gal drum from a food industry. Such as vegetable oil or something like cooking oil, etc! They often have a liner inside so make sure to burn the hell out of it!!! Im in the midst of creating a smoker from one! Should be able to hold a few turkeys when I'm done.


SoCal

Use a 55gal drum from a food industry. Such as vegetable oil or something like cooking oil, etc! They often have a liner inside so make sure to burn the hell out of it!!! Im in the midst of creating a smoker from one! Should be able to hold a few turkeys when I'm done.


SoCal

Got any pics of the progress?

My dad and I made one. Just like others have described....cut barrell in half, weld on some hinges, weld on some legs, cut hole for vent and that is it. We've since upgraded to a larger square one made out of sheetmetal...has a removable lid with a handle on each side, large door for adding wood, vents, and a huge rack, its big enough that we can get both halves of a pig on, and a few other pieces of meat. Its not very mobile though.

Its not very mobile though.

screw mobility! sounds like a nice setup.....let the party come to you!

Thanks for the insight. i will look into all the option. as far as the steel putting off poison gases i would think it would come from the stuff the put on the bare metal to prevent rust. i would burn mine really hot for about 8hrs to get any toxins off the metal.
NO! Do you actually think a steel mill paints the sheets of steel that go to a fab shop?? It is just bare steel and steel gives off fumes when burned or heated to high temps. But as long as you're informed it is up to you what you want to do.
Use a 55gal drum from a food industry. Such as vegetable oil or something like cooking oil, etc! They often have a liner inside so make sure to burn the hell out of it!!! Im in the midst of creating a smoker from one! Should be able to hold a few turkeys when I'm done.


SoCal

Yes, anything from the food industry (stainless steel) should be ok and will be the best choice.

http://www.thesmokering.com/pits/metalpit/bigbaby/default.jsp

http://www.bestcontainers.com/


http://www.azbbqa.net/index.php?option=com_content&task=view&id=12&Itemid=56

http://www.lincolnelectric.com/knowledge/articles/content/bbq.asp

Damn good links!

my oster charcoal grill is not made of stainless, just steel.
all of the mini portable grills i have are made of steel, not stainless.

my oster charcoal grill is not made of stainless, just steel.
all of the mini portable grills i have are made of steel, not stainless.

Are the grills coated? I know my grills have a coating on them when I first buy them.

I don't know, I'm just relaying what I was told by my welding supervisor, who gave very good detailed explanation about it and also relaying what I read on a warning sticker on a plate that came from the steel mill. It is up to the individual what they want to do.

well, the all have paint on them. there are rust spots now on some of the older grills. i have heard that some metals are not suitable but am not sure which ones. if you look at the big smokers and grills at the stores, many of them appear to be regular old steel.

I don't think it's paint, but there is a coating on the grill. If I were to build a bbq, I would find out what is ok to use for the bbq itself and the grill by contacting the manufacturer or a trade school may even know. If using a 55 gallon drum was in fact ok, I would not use one that contained fuels of any sort or chemicals

your right its not just paint it is high temp paint i e grill paint as long as you paint it with that it should be fine which i don't care to eat off of them without it and have many times in the past/ i know i'm alittle late on the post but i was about to build another one and was getting some ideas from other people is how i stumbled on to these posts. but if you have already made one i would like to see the pics.

Got any pics of the progress?

Google it.I was just looking at them last week.Tells what to use right and how to build,right down to the grates.'For 55 gallon smoker I think they were weber grates.

Good luck on your project