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Brick Barbecueby solelord on May 12, 2009

Table of Contents

License:   Attribution Non-commercial Share Alike (by-nc-sa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Intro:   Brick Barbecue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 1:   Good excuse to build a new BBQ! (pouring the concrete walk) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 2:   Concrete walk poured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

step 3:   The next day after the pour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 4:   First course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

step 5:   2nd course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 6:   3rd course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 7:   4th course . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

step 8:   Building the smoker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 9:   Firebrick set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

step 10:   Lentil for the opening over the firepit door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

step 11:   Laying up the first red brick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

step 12:   More brick! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

step 13:   Concrete lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

step 14:   Finshing up the top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

step 15:   Whats concrete without some steel? hmm? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

step 16:   Car Jacks and a steel drum? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

step 17:   Grilling Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

step 18:   Smokin' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

step 19:   Damper Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

step 20:   Sole's Pit Master Barbeque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

step 21:   Sole's Pit Master Barbecue (Update) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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License:   Attribution Non-commercial Share Alike (by-nc-sa)

Intro:  Brick BarbecueBuild your own brick barbecue! With few skills and tools this is something anyone can do!This is the fourth brick barbeque I have built. They are fun to build and cook on.This time I wanted a large firepit with a smoker on the right side.I went in thinking this was the last one lolThe grilling side is about 45 inches long by 30 inches deep. The smoker is 30' deep, 28 wide 30 tall.

step 1: Good excuse to build a new BBQ! (pouring the concrete walk)Seeing how we wanted to pour some concrete for a new patio/walk, why not build a new BBQ from brick. Soooo we got to work and included some rebar where the BBQwould go.

step 2: Concrete walk pouredEven though I measured the location of the rebar time and time again, I still got a little nervous lolToo late now!

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step 3: The next day after the pourShowing again the locations of the rebar. I wanted to make sure I had reenforcement in certain areas.

step 4: First courseUsing 4" partition block, I set the first course trying to keep things straight, plumb and level as I could.

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step 5: 2nd courseWith the 2nd course almost finished and my son wanting to contribute to the project, we made up a form for the lentil. I constructed the lentil with two pieces of 1 1/2"angle that suported and cradled firebrick. We then made the plywood form and hung 1/2" rebar length wise and tied that into the vertical rebar. We then poured it usinghydraulic cement until the cavities of the first and second course were filled and the form as well, making sure all the air bubbles were out.

step 6: 3rd courseThe lentel looked like it turned out fine, we ended up with a rock solid structure that included the first and second course of block.Note: All rebar locations were filled with hydraulic cement every second course.

step 7: 4th course4th course set for the most part, still trying to keep things straight level and plumb.

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step 8: Building the smokerThe next 2 course have been set, completing the side for the smoker. Again, every 2 course of block laid, the cavities were poured using hydraulic cement at all the rebarlocations. I will wait to install the second lentel until after I have set all the firebrick inside.

step 9: Firebrick setI went to my local building supplier and purchased standerd size firebrick and used those for the floor of the firepit. Then I purchased 1 1/4" thick firebrick for the walls ofthe firepit. Here's a view showing the opening to the smoker. you can also see that I installed a solid 1/2" rod through the block as well. I then welded a solid steel plate tothe rod to act as a damper for the opening to the smoker.Note: I used 3 lbs of FireClay to an 80 lbs bag of premix mortar to set the firebrick. I dry mixed the fireclay and premixed in a mixing tub and then dumped it all in a cleanplastic garbage can that had a good fitting lid.

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step 10: Lentil for the opening over the firepit doorSame as the other lentel, using to pieces of 1 1/4" angle, firebrick sandwiched between them at the bottom with wire mesh and rebar hung in the form.

step 11: Laying up the first red brickFeeling really good this day I managed to lay up a good deal of the red brick I had purchased at my local building supplier.The days have been rather hot and the old dude is showing his age lolNot bad for an old fart at this stage of the game lol

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step 12: More brick!With some more brick, more angle to support the firepit opening and another rather hot day I manage to set a few more brick.

step 13: Concrete lidI made a concrete lid 2" thick with an opening for the chimney. I used wire mesh and 1/2" rebar for the renforcement, then with the helps of my son and a friend of his, weinstalled the lid, mortaring it in place with a slight drain to the back.Note: I made a wooden box 2 inches deep, tied the wire mesh and rebar together making sure it stayed supported in the center of the form. I then mixed up three 50 lbsbags of hydraulic cement and pour the form. After screeding the form I then covered it with plastic and let cure for 3 days before removing anything.

step 14: Finshing up the topLaying more brick getting the top finished

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step 15: Whats concrete without some steel? hmm?Visiting my local metal supply paid off. They had everything I wanted and more lolThe grill and smoker door I cut to size after making the frames. The top pieces for the grill and the chimney hood were cut to size from the kind folks at my local metalsupply. I found someone to bend the chimney hood through my metal suppy as well.

My friend next door had some nice 8" tile just the right color, why not use those to finish the top of the smoker with hmm? Makes a real nice surface to put a plate on :)I bought my stainless steel spring handles and my weld-on hinges on-line.Everything else came from the hardware store.

Image Notes1. Bullet style weld-on hinges keeps the look clean and sturdy2. Stainless steel spring handles won't rust and keeps things cool3. Damper door for the smoker to regulate air flow

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step 16: Car Jacks and a steel drum?They are cheap lol pleantiful and I get to do a little recycling lolTwo car scissor jacks and one clean used 55 gal drum.Some flat thin metal welded to the top and bottom of the jacks for more stabilty. The drum cut to size with a sawsall for fire baskets.I raise and lower my fire baskets as needed. Has been real usefull.

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step 17: Grilling Racks3/4" square tubing and some expaned metal. 1/8" steel rod for small handles.I made the top frame to include the hangers for my racks.I wanted two levels and I wanted them to slide back and fourth as well.I can have to differant fires going and also have the option at which level.Knowing that I would want to cook most anything (even hotdogs without having to start a fire) I found a guy online that described how to construct a pipe burner in fulldetail.Back to the metal supply I went for some 1 1/4" black pipe lol

Here's a link showing how to make a pipe burner.http://www.hobartwelders.com/weldtalk/showthread.php?t=28224

step 18: Smokin'With a visit to a local use appliance joint, I picked up two racks for free! Little farther down the road to another used joint and got two more racks for 5 bucks lolI welded them together to make one large rack each. I also had to weld up some small flat metal to make them fit my needs for width.The springs for the handles on the back of smoker and grill doors are from the seat of a riding lawnmower (the riding lawn mower is now a racing mower of sorts lol nouse for these springs any longer lol) I used these to keep the tension on the handle to make them operate properly. Some flat steel bent to act as a latch on the inside ofthe door frame keeps the doors closed rather nice.Finished off with a nice large easy to read temp gauge.

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step 19: Damper SetupA photo and some crude drawings to help illustrate how I setup the intake damper.

The exhaust damper is nothing more the a flat piece of steel slid over the chimney to regulate heat flow.

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step 20: Sole's Pit Master BarbequeAmong other names lolI have kept my fires small so far. Only some light grilling and short test runs with the smoker.Making sure it dries out slowly.

One cheap Gas Grill on its way out the door lol needs a gas bottle, first come takes it lol

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step 21: Sole's Pit Master Barbecue (Update)What a great summer of outdoor grilling it has been!The smoker keeps a nice even temp once warmed up which does not take long!I have smoked several pork shoulders and ribs, including beef ribs and a brisket and more yard bird then I can remember lolThe fire pit has been awesome as well!Appetizers like bacon wrapped shrimp to grilled stuffed jalopenos, grilled fruit, veggies, corn, taters, you name it! All turns out great!I have two nice turkeys to put in the smoker for Thanksgiving. The large one is 17 pounds and the other one is 12 pounds.Looks like I will be up early!Mmmmmmhmmmmm I can almost taste it now!Happy Thanksgiving everyone!

PS  here's some  more photos!

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Image Notes1. The flame and smoke rushes through the damper into the smoker. Controlingthe air intake controls the temp

Image Notes1. 230 degrees and steady. Stoke the fire and throw that Boston Butt and ribsin there!

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Comments34 comments Add Comment

 stuart_horton says:  Feb 4, 2010. 11:48 AM  REPLYnice pit!!!!Is their anything that you would do different, if you were to build this pit again?

 mikej_w says:  Jan 28, 2010. 7:55 AM  REPLYFrom the experience I have with my store bought smoker, I would suggest a different arrangement for the damper, where you have finer control over theamount of smoke admitted.Make a sliding door (a flat piece of metal), and a slot in the unit so that the door slides from the front of the unit, across the smoke opening. Make the slidingdoor with a taper on the far end, so that when the door is almost fully closed, you have a greater amount of control over how big the opening is. The doorcould have a wooden or stainless handle to adjust with on the front of the unit, it would end up near the "sawblade", perhaps a little above it.The farther the door handle is pushed in, the more closed off it becomes. You might want a metal slot for the door to slide in.Maybe somewhere down the road, I can an instructable, one inspired by your beautiful project!

 DIYorNotAtAll says:  Jan 24, 2010. 3:41 PM  REPLYThis thing rocks! I just finished measuring for my patio extension so I can get started and have this built by spring.Cant wait to do a whole hog over the grill side..........

 cojonc says:  Aug 6, 2009. 9:37 PM  REPLYWhat is a lentel? Could you explain it's derivation, structure and use please?

 kill-a-watt says:  Dec 25, 2009. 8:03 AM  REPLYI think he means lintel

http://images.google.com/images?q=lintel+brick

 misterwelder says:  Nov 28, 2009. 8:40 PM  REPLYThat's a great design and use of materials. Two thumbs up on all of your craftsmanship.

 remedo says:  Nov 9, 2009. 1:47 AM  REPLYI use a metal smoker and I just built an outdoor kitchen with a drop in Jenn-air grill that uses natural gas.  I am planning on building something very similar towhat you built out of cinder block to replace my smoker.  My question to you is does your smoke chamber have some sort of drain?  When I smoke brisketsalot of grease ends up at the bottom of my smoker that I have to drain.

Thanks and great job!!!

 solelord says:  Nov 25, 2009. 12:15 PM  REPLYOutdoor kitchen! Awesome!I dont have a drain, however I do have a series of drain holes in the back side at bottom of the smoker. It hoses out easy.I have seen drains installed in the bottoms of brick smokers and decided not to. I didnt want to deal with the plumbing or any problems that might comefrom it.A mason bit and some wood dowels to plug the holes when cooking works great.I made drain holes the same way in the grilling side for the same reason.

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 KuddlKat says:  Sep 28, 2009. 2:29 PM  REPLYThis is probably a stupid "grilling noob" question, but isn't it hard to clean the expanded metal afterwards?

 solelord says:  Nov 25, 2009. 12:01 PM  REPLYLike you would season a good cast iron skillet, I treated the grilling racks much the same.I brushed down the racks, top and bottom with cooking oil, then let the excess drip off. I then put them over a hot fire.I did this a couple of times before cooking on them.Now they are seasoned very nicely, nothing ever sticks either. 

 KuddlKat says:  Sep 28, 2009. 2:27 PM  REPLYMany thanks for that link to the pipe burners. I've just been admiring the construction of this whole thing even though I live in a townhouse and something likethis is out of the question, but it never occurred to me that I could retrofit my old refurbished wood/charcoal grill into propane without costing $100+... I waswondering if the pipe burner wasn't too close to the side wall? It looks like it might be only ~3" and the fire bricks don't come that far up. Great ideaincorporating that into the project though.

 solelord says:  Nov 25, 2009. 11:49 AM  REPLYI dont use the pipe burner often, hotdogs are about the only action it really gets lolYour right the burner is close but it's really about 6 inches from the wall, seams to not heat up as much as you would think.

 cojonc says:  Aug 6, 2009. 10:00 PM  REPLYYou put "lol" in a lot of places. I'm confused. Does that mean anything or is it just a leftover from incorrect XHTML or something on that order. I think I haveseen it before and it's always the same. By the way, great job and that's a super grill. Instead of a hand held drill why permanently install and wire up a smallinexpensive 120 V motor to raise and lower that ... whatever it is. Why do you need to raise and lower that something, and what does it do?

 KuddlKat says:  Sep 28, 2009. 2:18 PM  REPLYThose fire baskets hold the wood/charcoal and he made it adjustable to change how close the heat and flames would be to the grilling racks. The motoridea is good, but he probably does not need to adjust them very often since the sliding grilling racks at different heights. Plus, it will get very hot downthere and having a permanent motor and wiring could be bad for the equipment.

 Kelticfox says:  Aug 18, 2009. 8:15 AM  REPLYlol is an accronym for "Laughing Out Loud".

 roxiel says:  Sep 18, 2009. 7:14 PM  REPLYALL I CAN SAY, I WISH I HAD THIS IN MY YARD! GOOD JOB! I CAN SMELL THE BBQ NOW!

 purplewg says:  Aug 25, 2009. 11:32 AM  REPLYThat is one sweet build. I bet you are proud. You also have less grass to mow now also. lol

 cojonc says:  Aug 6, 2009. 9:50 PM  REPLYLooks great! Huge though isn't it? Looks like you could roast a whole goat on that. Hmmm, not a bad idea. . .

 cojonc says:  Aug 6, 2009. 9:35 PM  REPLYWhat sort of brick is that? Did I hear somewhere that concrete brick will soon crumble from fire? Is that special stuff even though it appears to be concrete?

 luvit says:  Jun 14, 2009. 6:56 PM  REPLYi cook over a 55 gallon drum each night and shoot the breeze with my buddies. then i go to sleep in my cardboard box.

 boomrlargo says:  Aug 4, 2009. 12:08 AM  REPLYYour box has wi-fi?? Sweeet...

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 anaemic says:  Jul 19, 2009. 7:08 AM  REPLYwow that is a really nice looking barbeque, still the amount of lol's in the article filled me with rage :p

 abadfart says:  Jul 14, 2009. 12:35 PM  REPLYvery nice ill try this when i have the money and time

 twoey says:  Jun 26, 2009. 10:57 PM  REPLYwow! that's a very snappy bbq pit. kudos!

 steed1172 says:  Jun 20, 2009. 6:08 PM  REPLYcan i get a price estimate?

 Gavin082 says:  Jun 14, 2009. 7:37 PM  REPLYYou need to put scorelines in your large concrete pad otherwise it will crack. It can be done with a float while the concrete is still setting or with a saw after ithas set. In reality, the scorelines/joints don't stop cracks but control where the cracks happen. You're just making sure the pad cracks in an attractive pattern,like a grid, but the point is it'll keep the pad looking nice and keep the concrete from crumbling as well. But awesome barbecue!

 valhallas_end says:  Jun 14, 2009. 7:28 PM  REPLYAdd a brick pizza oven on the other end and you have all your critical food groups :-P

 solelord says:  Jun 14, 2009. 6:40 PM  REPLYThank you everyone! Yup I think I had food on the brain when I was spelling Lentel lol Thanks Yosh! Hope to get some more pics up soon. Guess I kindaforgot about the damper lol

 jessyratfink says:  Jun 14, 2009. 10:29 AM  REPLYImpressive! It looks insanely professional. :D

 DngrDave says:  Jun 14, 2009. 9:14 AM  REPLYThat's one serious looking barbeque. I wish I had the space and resources to build something like that.

 Luki101 says:  Jun 14, 2009. 6:13 AM  REPLYThat is one nice lookin' barbeque. I envy your skill and your grill.

 yoshhash says:  Jun 14, 2009. 6:11 AM  REPLYgreat instructable. One thing, though....I'm sure you mean lintel wherever you wrote lentil. I say this in case anyone is googling it and only getting souprecipes, hahaaha.

 omnibot says:  Jun 14, 2009. 1:33 AM  REPLYThat is a beut BBQ! Only thing I'd do differently is some sortof pattern on the concrete walk, looks a bit plain next to that amazing BBQ. Great job and aninspiration for when I get a house.

 SeamusDubh says:  Jun 13, 2009. 8:59 PM  REPLYDo you have any shots of the damper set up.?