The Texas BBQ Forum

ok in my introduction i mentioned a grill that I had someone make. Well, the story goes like this. The guy that made the grill made it out of an old air compressor tank. He said it was 44 gallon, i say it's 33 gallon. for arguments sake we will just say i'm right and he's wrong. I anticipated a larger grill, but it didn't happen. He pretty much just did what he wanted with some metal lying around and over charged me. It wasn't the ideal transaction, and a lesson well learned.

So now my plan is to modify the current tiny grill. learn a little about metal working and then when ready make the grill i would rather have.

So the grill had no straight lines, or level or straight anything. The grill had no ventilation. I've installed a vent. Nothing sat flush on the lid. I started to seal that up, but then decided the opening was way to small. More on that later. The grate that was included was, to say the least not good. The smoke stack was made with I believe 2'inch square. I believe it to be to small, it could be my opinion.

So the plan is to, make the opening bigger, make a new grate, level it up, and change out the stack.

Below are some pictures for your viewing and all input is welcome. I'm including some ideas i have.

The grill


ventilation installed




The pedestal that needs fixed - probably going to find a plow disc, or figure out how to level this. Probably going to go with a plow disc.



The door, it's way to small. I'm wanting to cut back to the far edge of tape measure, on top. a little over center on the top. Then cut down an inch to inch and a half on bottom. Then after that set it up for a slide in grate with

This is the idea for the door, cut to just over center on top. Then cut lower part of door down another 1 to 1.5 inches. make a new door, and then install some slide brackets for a slide in grate. Will i be ok on this? For the door i'm going to use some 1/8 thick steel, and some one inch strips on sides. But getting it squared and prepped first. Thanks for listening.

When you say build a new door are you talking about having a door rolled? If so save your money and just start over on a new tank because it is not worth it in my opinion.

So start over completely? Or just its a waste of time for the door? I can understand the door. I think I could do it, I have a crazy idea on how to do it. But your probably right it would be a waste of money. My next idea then, is to put strap pieces around the periphery of existing door and open it as much as possible. Better idea?

What I am saying is if you plan on going to a shop and have them roll you a new door to fit your larger opening it will be costly. It would be cheaper in the end to just find another tank and build what you want instead of what the guy building your first one thought you needed.

Ahh ok, I was planning on useing this tank as my learning project. I've got a plan crazy as it is and I'm not scared of the sight of my own blood. My lid idea is to use existing tank and bend some new 1/8 flat over it. Using straps / chains and some heat. Then cut it up to fit. My grandpa was a black smith and I swear I remember seeing him doing this. K.A.M i am appreciating your input. My ultimate plan is to build what I want, but I want to learn a little first. Thanks again

I look forward to following your progress.

Progress so far

I've leveled the base, I added a flat plate to existing base. Cut a circle out of some 1/8 plate. Circle turned out decent and I don't have to worry about tipping over any more. I have a plow disc. I haven't abandoned that idea yet. Its probably what I'll come back to, for looks only. The new plate base Is not perfectly flat anymore. Got it pretty hot during welding.

About welding, until yesterday I had never welded. I may be addicted it's fun and frustrating. I can't wait to get back out there. It's just fun doing something you have no idea how it works, and figuring it out on the fly.

I've also formed the new lid. Grampas old trick worked pretty good. Still needs some tweaking but very close to being where I need it.

Next step is determine new opening, and make and install new grate slides

Whats your plan to finish shaping that plate? honestly with that method I don't know if you will ever get it close enough to seal up well

Well I only have about a half inch More to go. I literally just talked to a guy at work that has a rounder in his area. I'm going to find out exactly what I need then mosey over to his area on a lunch break and finish rounding it out. So far this repair/ mod hasn't cost me anything but beer. Very lucky fortunate, or I only know alcoholics.

LOL! Hooray for alcoholics!
Excellent homegrown engineering!