With the onset of the summer season, the issue of organizing a high-quality place for cooking meat over a fire becomes especially relevant. Market proposals often suffer from either high cost or the use of thin metal, which quickly burns out and deforms when exposed to high temperatures. In such a situation, an excellent solution is grill made of disks, created with your own hands from car wheels. This is not only budget savings, but also the opportunity to get a truly durable structure.
Reusing old truck or car rims is an ideal example of smart upcycling. The thickness of the metal in such products ranges from 3 to 6 millimeters, which fundamentally distinguishes them from purchased steel analogues of 1.5–2 mm. Cargo rims have a sufficient depth of the bowl, allowing you to add a layer of coal and create the correct thermodynamics of frying without burning the food. Any person who has minimal skills in working with a welding machine and an angle grinder can do such a thing on their own.
In this article we will analyze in detail the entire creation process, starting from the choice of source material and ending with finishing painting with a heat-resistant composition. You'll find out why steel disc better than sheet metal, how to correctly calculate the height of the legs and what tools will definitely be needed in the work. The finished result will become not only a functional tool for cooking, but also a stylish element of the landscape design of your site.
Selecting a suitable disk and preparing materials
The first and most important step is to find a suitable foundation. To create a high-quality barbecue, wheels from trucks (for example, KAMAZ, ZIL, GAZ) or from large-sized special equipment are best suited. The diameter of such products is usually 20 inches or more, and the depth of the rim allows you to comfortably place skewers. Car wheels (R13–R16) can also be used, but the frying zone will be too small, which is inconvenient for a company of several people.
When examining the found metal, pay attention to its integrity. Although we will be cutting out part of the design, the original geometry is important for the symmetry of the future product. Heavily rusted metal will have to be stripped down to the living layer, which will take extra time, but it will be worth it. Wall thickness - the main parameter that ensures heat resistance and uniform heat distribution. The thin metal cools quickly, causing the meat to simmer rather than fry.
⚠️ Attention: It is strictly not recommended to use wheels made of light alloys (cast wheels). When heated, aluminum loses strength, can melt or, worse, ignite bitumen and fuel residues with the aggressive release of toxic substances. Only steel!
In addition to the disc itself, you will need to prepare a number of related materials. For the legs, a square profile pipe of 40x40 mm or a corner of 50x50 mm is perfect. If you plan to make a stationary structure, the pipes can be concreted. The mobile version will require wheels or reinforced legs with crossbars. Also don't forget about heat resistant paint (coxolitic or silicate-based), which can withstand heating up to 600–800 degrees.
Necessary tools and protective equipment
The quality of workmanship directly depends on having the right tool. The main work will be cutting metal and welding joints, so having a working welding machine (preferably a semi-automatic one, but an inverter with 3 mm electrodes will do) is a must. A grinder (angle grinder) will be needed for cutting metal and cleaning seams. The diameter of the cutting wheels must correspond to the power of the tool, usually 125 or 230 mm.
For marking and measuring, use a tape measure, a metal ruler and a scriber or metal marker. To ensure that the barbecue is level and the skewers do not fall, you will need precision down to the millimeter. A drill with a set of metal drills will also come in handy if you decide to make holes for blowing or attaching additional elements, such as a shelf for firewood or hooks for accessories.
- 🛡️ Personal protective equipment: welding mask (“Chameleon”), thick leggings, closed shoes and clothing made from natural fabrics.
- 🔧 Locksmith tools: hammer, chisel, clamps for fixing parts during welding, grinding wheels.
- 📏 Measuring tool: tape measure, square, level (to check the horizon when installing the legs).
- 🎨 Consumables: cutting and grinding wheels, electrodes or wire, degreaser, primer for metal.
Safety when working with metal comes first. Sparks from grinders and welding scatter several meters, so the workplace must be cleared of flammable materials. Ventilation indoors is also important, especially when removing old rust and paint, the dust from which is harmful to the respiratory tract. If you work in a garage, provide fresh air.
☑️ Checking readiness for welding
Manufacturing technology: step-by-step instructions
The process of creating a barbecue can be divided into several logical stages. First, the disc is initially cleaned of dirt, old rubber (if it still exists) and loose rust. Then the cutting line is marked. Usually one of the side shelves (rims) is cut off from the disk, leaving the central bowl. The height of the side of the finished grill should be 13–15 cm, which is the optimal distance for frying shish kebab.
It is better to cut metal along the outside of the disk, stepping back the required distance from the center. If you are making a barbecue from a weight disc, it is often enough to simply cut off one of the flat sides, turning the product into a deep bowl. For passenger wheels that have a complex shape, it may be necessary to cut out the central part and weld it to the ring, or use the entire disk if its depth allows. After cutting, the edges must be thoroughly cleaned with a flap wheel, removing burrs.
The next stage is the creation of a supporting structure. The legs can be welded directly to the side of the disk or a separate frame-stand can be made on which the bowl will be removably installed. The second option is more convenient for transportation and cleaning. If you are making a stationary grill, you can cut holes in the lower part of the bowl (formerly the center of the disk) for blowing air, which will provide better heat for the coals.
The secret to a perfect cut
To make the cut with a grinder smooth in a circle, you can make a simple template from a strip of metal or plywood. Secure one end of the template in the center of the disk (for example, on a bolt), and at the other end make a hole for the body of the angle grinder. By moving the tool in a circle, you will get a perfectly straight cutting line without distortions.
The final assembly includes welding of carrying handles (if the barbecue is mobile) and fastening elements for skewers. As limiters for skewers, you can use slots cut in the side with a grinder or weld small metal ears with notches. All welds must be cleaned to improve appearance and prevent the accumulation of moisture, which leads to corrosion.
Improved design: blower, handles and shelves
The basic version of the grill is functional, but additional elements make the cooking process more comfortable. One of the most important improvements is the organization of the correct blowing. At the bottom of the bowl, where the center of the wheel was, there is often a technological hole or thinning of the metal. It can be used by drilling a series of 10-12mm diameter holes in a circle or by making several large cuts. This will provide oxygen to the coals, allowing them to burn faster and hotter.
To make it easy to move a heavy structure (the weight of the load disk can reach 15–20 kg), reliable handles are needed. They can be made from reinforcement, bent into the shape of a bracket, or you can use ready-made furniture handles made of metal, welding them through reinforcement plates. It is better to place the handles on opposite sides of the bowl to balance the weight when carried by two people.
| element | Material | Function | Difficulty |
|---|---|---|---|
| Carrying handles | Reinforcement d10-12 mm | Transportation of the barbecue | Low |
| Firewood shelf | Mesh or rods | Fuel drying and storage | Average |
| Poker included | Metal rod | Moving coals | Low |
| Cover | Metal sheet 2-3 mm | Protection from rain and ash | High |
A useful addition would be a lower shelf for firewood or dishes. It can be made in the form of a grid of reinforcement welded to the legs at a height of 30–40 cm from the ground. This is not only convenient, but also adds rigidity to the structure, preventing the legs from becoming loose. Hooks for a ladle, brush or gloves can be welded on the side, turning the grill into a full-fledged workstation.
Use old door handles or car trunk handles as ready-made ergonomic barbecue handles. They already have a convenient shape, coating and can withstand loads; all that remains is to weld them securely to the body.
Corrosion protection and finishing
Metal, especially after welding and heat treatment, is subject to rapid oxidation. To your grill made of disks served for decades, and did not rust after the first rain, proper finishing is necessary. Ordinary enamels will not work - they will burn at the first ignition. It is necessary to use specialized compounds.
Before painting, the surface must be degreased (you can use white spirit or gasoline) and coated with heat-resistant primer. Then enamel for stoves and barbecues is applied. Such paints can withstand temperatures up to +800°C and often contain aluminum powder or silicone resins. It is better to apply the composition in 2-3 thin layers with intermediate drying, following the instructions on the can or jar.
⚠️ Attention: Before first use, be sure to heat the grill outdoors without food. This is necessary to burn out any remaining solvent, factory lubricant, and paint polymerization. The smoke when first lit may be acrid and unpleasant.
An alternative to chemical painting is bluing or firing. When fired, the metal is heated to a blue color, forming an oxide film that protects against rust. However, this method is labor-intensive for large products. A simpler option is to coat it with edible oil and then heat it, which creates a natural anti-corrosion layer that is safe for contact with food.
Proper painting with heat-resistant enamel extends the life of the grill by 3-4 times and prevents corrosion products from getting into food, which is critical for health.
Frequently asked questions (FAQ)
Which disk is better to choose: from a passenger car or a truck?
It is definitely better to choose a wheel from a truck (KAMAZ, ZIL). It has a greater bowl depth (about 20 cm versus 7-10 cm for passenger cars), which allows you to pour more coal and creates the right heat zone. The discs are too small, the meat will be too close to the fire and burn, and the coals will cool quickly.
Do I need to drill air holes in the bottom of the grill?
Yes, this is desirable. Holes with a diameter of 10–15 mm in the lower part of the bowl provide the draft necessary for burning coals. Without ventilation, the meat will take longer to cook and may develop a smoky smell. However, do not make the holes too large, otherwise the ash will spill down, staining the ground or your feet.
How to paint a barbecue so that the paint does not burn?
Use special heat-resistant enamels (KO-8101, KO-811 or aerosols labeled “for stoves and barbecues”). They can withstand heat up to 600–800 degrees. Regular nitro enamel or alkyd paint will burn off the first time you use it, leaving an unpleasant odor and appearance.
Is it possible to make a grill without welding?
It is difficult to make a full-fledged grill without welding, since the disk needs to be cut. However, you can not weld the legs, but make a removable structure: a bowl made of a disk is installed on a pre-welded or bolted stand. The bowl itself can be cut using only a grinder if you find a disk with thin walls, but this will require a lot of effort.