How to Turn an Oil Barrel into an Economical Barbecue! 2026

How to Convert an Oil Barrel into an Economical Barbecue, this is a great project, relatively cheap, that will keep you entertained for an entire season. This oil drum barbecue always ends up lit at every party and actually becomes the centerpiece, getting a lot of attention.

Whatever joint you decide on, wrapping it in layers of aluminum foil will protect it from heat and keep it tender and succulent!

Step 1: What you will need

Below is a list of tools and materials you will need to complete this project. Remember that safety is very important. Always use appropriate safety equipment when fabricating with metal.

• Mig welder + wire, mask, gloves
• Angle grinder+ cutting discs, sanding discs, grinding discs
• Hammer
• Hacksaw
• Squads
• Rule
• Tape measure
• Bookmark
• Drill
• Drill set
• An old oil drum
• High temperature barbecue paint
• Steel hinges
• Chrome hook
• Barbecue temperature indicator
• Safety glasses and gloves
• Steel box
• 6mm mild steel round bar
• U-shaped safety edges
• Steel sheet strips
• Stainless steel grate or stainless steel mesh
• Nuts and screws for hinges and frame
• Large steel chimney pipe

Step 2: Remove the paint from the oil drum

Before doing any work on the oil drum, it's definitely worth checking what's inside. Be very careful if there have been flammable liquids inside, as they could ignite during grinding. If you are unsure I would advise asking someone! Any remaining liquid should be discarded accordingly.

For this stage, you will need the paint removal disc for the angle grinder. You can also use a wire brush attachment for a drill, but I found the angle grinder removes it faster!

Step 3: Weld the chimney

The large diameter (70mm) steel tube was cut at 45 degrees and then welded together. It is important to ensure that the weld bead is around the chimney to prevent smoke from coming out of the joint. I use a Clarke 160EN Mig welder. Be sure to wear appropriate safety equipment when welding: Gloves and mask.

Step 4: Cutting the lid

Mark the cover of a quarter cut using the engineers chart, ruler, and permanent pencil or marker. Carefully cut along the lines using the angle grinder with the cutting disc. It is a good idea to rest the oil drum on something stable to prevent it from getting dented when cutting.

Step 5: Weld the side strips on the lid

Weld some thin strips of mild steel sheet metal to the sides of the oil barrel. This will create a gasket that will prevent the lid from falling off when closed. It will also add rigidity to the lid, keepinggetting that curved shape. Secure the strips in place using the welder every inch or so.

Step 6: Clean the inside of the Barbecue

This stage is not as glamorous, but it is definitely necessary. You should clean the inside of the oil barrel to ensure that all oil residue has been removed. There are two reasons to do this:

• The paint will not stick if there is oil residue.
• The barbecue will emit a large amount of thick black smoke if oil remains inside.

I tried many ways to remove this oil. I tried burning it (it doesn't really work and leaves a big mess that's even harder to remove)! The best method was to use a degreaser that you might have in your cupboards to clean the oven! This was very effective at removing the oil!

Step 7: Making the folding frame

This is a folding frame that consists of two rectangles that fold into each other. The dimensions of this frame are completely up to you and depend on the size of the oil barrel you have.

Using a hacksaw, cut the various lengths of steel box section you need. When you weld the two rectangles, keep checking with the engineers' cadre to make sure that the right-angle joints are completely square.

Mark the centers of each side section for the legs. This will be the point at which the frames will rotate. Center the marks on the punch and then drill with a small drill bit until you reach the desired size for the bolts.

When the two parts of the frame are joined together, the frame needs to be placed in the correct place so that the oil barrel rests on top. At this point, there is nothing to prevent the frame from falling. Tie two pieces of rope around the top halves of the frame to prevent the frame from falling over. 4 pieces of steel bar need to be welded to the frame just above and below the hinge. This will form the background mechanism to keep the frame at the correct angle when open. When the frame is closed, it folds.

Step 8: Attaching the lid hinges

The hinges need to be placed on the oil barrel and the holes marked with a permanent pen. It is vital to ensure the lid is in the correct place before marking the hinges.

Center the holes in the center and then drill with a small hole first followed by the correct size. Secure the hinges to the oil drum with nuts and bolts.

Step 9: Add the security trim

U safety edges should be placed on the straight, sharp edges of the lid and oil barrel. It's a good idea to glue it on the inside to hide the welds.

Step 10: Attaching the handle

The handle is made from a square section of steel. The handle is first welded as a sub-assembly and then welded on the cap in the middle. Be sure to remove all chips created when cutting the steel.

Step 11: Adding the Grill Brackets and Hooks

The main grill is supported by a steel bar that extends through the interior of the barbecue. This then forms the outer handles on both sides. The steel bar is welded into place and then the bars are welded together to form the handles. When attaching the rods, make sure the holes are in exactly the same place on both sides of the oil barrel. 3 small hooks are welded on the side which form small holders for barbecue tools.

A large hole is drilled in the bottom of both sides of the oil barrel to form ventilation holes. Small holes are drilled in the middle of the barbecue to create drainage holes. A hole is drilled in the lid for the temperature gauge.

The chrome hook is placed in position on the lid, marked and then drilled. Small screws and nuts that keep it in place.

Step 12: Creating the grill

For this part, you can purchase a grill that has the correct dimensions or you can make one yourself. With either method, you'll want to make sure stainless steel is used as you don't want bits of rust on your food! This is one of the things that struck me when I started looking at competing oil barrel grills: many of them use mild steel for the grills! I make all my grills using stainless steel for the food contact parts!

Step 13: Everything complete!

Congratulations, your BBQ is complete!

Thank you for reading!

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