Worths Idiot Grill.

[worth1]

Thought I would move the build over to the workshop section.
Went to the metal yard and picked up a 4'X8' sheet of 3/16" plate steel.
The whole thing weighs close to 250 pounds.
Then I stopped off and got some fire brick.
The fire brick is going to dictate how to build the main body of the grill.
Yes fire brick on the bottom and sides of the grill.
I figure about half of the 4X8 sheet will go into one grill assembly more or less.
These two items alone are the most expensive part of the grill with the cost of the other materials tapering down from that.
Could have bought the fire brick for less but didn't want to drive across country and into Austin to get it.
Total design not finished but needed some place to start.

[worth1]

Here's the stuff so far.
There wont be any fire grate the coals will sit directly on the fire brick.
Commonly known as an Argentine Brasero grill.

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[worth1]

With 5 more fire brick I can make the inside area 46 inches wide and the depth 22.5 inches.
This will give me the ability to make two grates close to 18 inches X 22.5 inches and leave me a space close to 10 inches for the brasero.
Of course I will have to shrink the grills a bit so they will fit.
This will also allow me to cut off a 4 foot by 2 foot section of the plate steel.
Right now I'm not thinking I will be able to mount this heavy monstrosity to that 4 inch pipe sticking up in my yard.
But as they say in for a penny in for a pound might as well make the thing the way I always wanted to and be done with it.
I can always mount a smaller down and dirty grill on the 4 inch pipe, you can't have too many grills.

[worth1]

This is it.
It may go up but not out.
Trying desperately not to cut fire brick.
But my fishing buddy has the cutter if need be.
I figure I will cut off the 2X4 piece tomorrow after the plate steel has cooled off and I will be able to close my tail gate.
It isn't like the stuff is getting in the way of anything in the back of my truck and who on earth is going to steal it?
Not like you would see a thief running down the street with a 200 pound 6X4 sheet of plate steel under his arms headed to the scrap metal yard for beer money.

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[worth1]

Lets talk money.
The 4X8X3/16 plate steel cost me tax and all $130.75.
The over priced fire brick at tractor supply cost $164.11.
I could have probably got it for half that price at the factory but just didn't want to deal with the trip.
294.86 so far.
Lets jut call it $300 and be done with it for crying out loud.
The reason for me to put out in public what the costs are isn't to brag but to only let me keep a record of what it is and to show folks what the materials cost are as opposed to the labor involved and skills required.
But lets look back, I am only going to use about half of the steel plate so we can cut that in half.
I should hope so.
So lets say 66-300 brings us back down to $ 234.00, not bad "right".
I always round my numbers up to make it simple.
I bet I can kick this puppy in for less than or close to $500's in materials, lets see.
Then after we have determined that, we will start to calculate what my time involved is and the labor.
Also dont forget the tools I use including some rather intricate stuff most people don't have.
This is an exorcise in me being able to be self employed some day soon.
I am getting old but need to be able to work on my time not others.
But most importantly it is for your entertainment.
Please respond with a thumbs up, comment, or tell me I am full of it.

[worth1]

Got a couple of C clamps to use for handles and drug the monstrosity out of the truck onto my homemade saw horses.
One saw horse at a time almost balanced.
I put my weight on the end and my neighbor slid the other one under the other end.
Slick as a whistle.
No heavy lifting.
Neighbor was impressed.
Then the arduous task of cutting out pieces with a cut off wheel.
Need plasma cutter but too expensive.
After cutting I dressed up all sharp edges to keep things safe.
This is good shop practice and a real must to do so.
The alternative hazard isn't acceptable.
I also use the C clamps to handle this stuff.
Makes life easy.
I also wiped down the top of the plate with hydraulic fluid to hold down the rust.

I have a ton of leaves to sweep on down the drive an into a planter bed.

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[worth1]

You get pretty inventive when you don't have help.
Plus C clamps are better anyway.
I'm not welding this but it is for demonstration on how to do it.
Or at least how I do it.
No need for some person to hold it.
There will be another long bar clamp every place I weld.
The other thing you must do is tack it all over the place or the metal will warp on you.
The angel iron is just a holding fixture not part of the build.

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[worth1]

If I would have known how hot it is outside I wouldn't have started this mess.
No wonder I'm soaking wet with sweat.
It's 92 F outside in the shade and I ain't in the shade.
Got a 12"X48" slab cut off and set up about ready to weld.
This stuff it wider than 4 feet and longer than 8 Feet by a wee bit.
Not really concerned about it as long as my cuts are square and accurate.

[EdieJ]

Don't get dehydrated!!!

[worth1]

[mention]EdieJ[/mention]
I'm not in any hurry, and haste makes waste.
Did some measuring and my cuts are dead on by about 1/32th inch or less.
If you start out sloppy it just gets worse as you go along.
I started life out as a framing carpenter many years ago as a teenager building houses from the foundation up.

I built the saw horses you see almost 20 years ago.

[bower]

Too true about measurement whether you are working on something big or small.
I have no talent for measuring, cannot draw a straight line and really, I can't see a straight line either. Can barely make a square out of cardboard.
Since I have made lots of things in spite of that, I do greatly admire those who do it right and have the knack.
For me it will always be a struggle. But the better the start, the better the end.
I have framed a few walls too, and thank god for precut studs.

[ponyexpress]

Looking good. What is that PVC contraption in the back of your truck bed?

It’s good that you have a nice project to work on. I keep my eyes open for 90s vintage Weber Genesis grills on FB and Craigslist to rehab for my collection. I have gotten a couple for free that were in great shape.

[karstopography]

Fishing Rod holders, the PVC contraption, am I not correct about that [mention]worth1[/mention] ?

Likely for surf fishing.

[worth1]

Yep rod holders for travel.
Cant stand tangled rods.

[worth1]

Got a brain storm on how to track the grills up and down.
Got the idea yesterday looking at some T rail they use to track elevator cars in the shaft.

[worth1]

Got out and cut up the two sides of the grill.
Then what I call dry fitting them to make any last adjustments before welding.
Everything looks good and came out exactly the way it should and as planned.
Keep in mind everything is in my head not on paper.
The box is the most important thing, it has to be square just like a cabinet.
The stuff you see my clamps are on are just clamping fixtures no part of the grill.
The machinist square you see I have had for 33 years.
[mention]Amateurinawe[/mention]
Notice where it was made.

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[worth1]

I cant make my mind up whether to buy a portable band saw or a metal chop saw to cut the smaller stock to build this thing.
I have used the small right angle grinder I am using to do it before and it sucks.
My Sawsall is out of the question, too hard to make accurate cuts.
I want accurate cuts of length at 90 and 45 degree angles, maybe I'm too picky.
Not willing to ruin my Skill Saw by putting a metal cutting blade on it like some people do.
Kind of leaning towards the band saw because I have many years using one and the lack of sparks.
I dont need to catch the place on fire with all my leaves and sparks flying around.
My TIG welder doesn't spark or at least it better not.
One thing good about needing welding supplies and metal is both are on the way home from work and literally about 100 yards from the highway on the service road right outside of town.

[Vanman]

I have portable band saws and a cordless DeWalt band saw. If it fits in the throat of the cordless it is my go to tool. Should have bought it sooner.

[worth1]

I have portable band saws and a cordless DeWalt band saw. If it fits in the throat of the cordless it is my go to tool. Should have bought it sooner.

Thanks for the input.

I have welded up the pieces I cut out and very satisfied with them.
Shouldn't have drank two cups of strong coffee, it gave me the jitters, with that and an occasional wind blowing my shielding gas out of the way I managed to do it.
That and I dont know how many years it has been since I ran the TIG welder too long for sure.
The good news is it is square.
Now that I have the thing together I can measuer what the (((real dimensions)) are to cut out the rest of it.
In one of the soon to be pictures it shows me using a 12 ton bottle jack a straight edge and a bar clamp to weld up the bottom plate.
Moved the jack around two times to get it as close as I could.
The seems were so close I didn't even have to use a filler rod welding at 130 amps.

[worth1]

Here is the progress so far.
The welding is on the outside back and bottom.

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