Reconstruction of old automotive components into useful household items is not just an economy class trend, but a real art of recycling, allowing you to give a second life to durable metal. Car-disc cuff It has become one of the most popular solutions for cottages and country houses due to its durability, aesthetic appearance and excellent heat resistance. Thick steel, from which wheels are made, is able to withstand enormous temperature loads without deforming under strong heat, which makes this material ideal for open fire.
Unlike cheap store counterparts made of thin tin, which burn out in one or two seasons, the design of the disc will last for decades. Alloy steel, used in the automotive industry, originally designed for extreme operating conditions, vibrations and shocks, so for a stationary grille, its strength characteristics are excessive, which only plays into our hands. Creating such a product with your own hands requires a minimum set of tools, but guarantees a unique item that will become the center of attention at any picnic.
In this article, we will analyze in detail the process of transformation (-) of a car wheel into a functional focus, consider the nuances of working with metal and suggest how to avoid common errors during assembly. You'll find out why. truck-disk It is often preferred to cars how to properly prepare the surface and protect the metal from corrosion after the first use. Readiness to work with a Bulgarian and a welding machine is the only thing you will need to start this exciting project.
Selection of the right disk and preparation of materials
The first and most critical step is the selection of the source material. For the creation of high-quality cladding, steel stamped discs are best suited, since they have the necessary wall thickness and ductility. Cast discs It is not recommended to use aluminum alloys: at high temperatures, aluminum can lose strength or, worse, begin to melt, and when cooled sharply (for example, if watered with water) it can crack. The ideal candidate is a disc from a passenger car with a diameter of R13-R15 or, even better, from a truck or tractor, as their dimensions allow you to cook food for a large company.
Pay attention to the condition of the metal: if the disk has deep through cracks or severe through corrosion, it is better to refuse its use. However, surface rust is not a problem – it will be removed during preparation. It is also important to take into account the diameter of the product, since the depth of the brazier and the distance to the coals depend on this, which directly affects the quality of the meat roasting.
⚠️ Attention: It is strictly forbidden to use for the manufacture of cuffs discs in which previously stored fuel and lubricants, petroleum products or chemical reagents, unless there is a 100% guarantee of their complete cleaning. Residues of oils during heating can release toxic substances that are dangerous to health.
To work, you will need to collect the following arsenal of tools and consumables:
- 🔥 Corner grinding machine (Bulgar) with a set of cutting and stripping circles on metal.
- 🔥 Welding apparatus (inverter) and electrodes of the corresponding diameter (usually 3 mm).
- 🔥 Drill with drills on metal to create holes for ventilation.
- 🔥 Metal brush for cleaning rust and old paint.
Additionally, you may need steel corners for legs or handles, as well as heat-resistant paint for finishing. If you plan to make a stationary structure, immediately think about whether the barbecue will stand on the ground or on a special pedestal.
Technology of cutting and forming the bowl
The process of turning a solid disc into a grill begins with marking and cutting. A standard disc consists of two main parts: a central convex part (plates) and an external rim. For a classic grille, we will only need a central part that will serve as a bowl for coals. The rim is usually cut, although in some design projects it is left as a decorative sideboard.
Marking the cutting line is most convenient to make with the help of a marker and roulette, retreating from the edge of the rim about 2-3 centimeters to maintain the integrity of the weld between the disc and the plate, if it is close to the edge. Cut should be carefully, trying to lead the Bulgarian perpendicular to the surface, so that the cut is even. If you use cargo-plateIts thickness may require a more powerful tool and careful operation to avoid overheating the metal.
Nuances of working with thick metal
When cutting thick-walled discs (more than 5 mm), the metal can "lead" from heating. Take small pauses, let the tool and workpiece cool, or use water to locally cool the cutting area (only if the drive is not connected to electricity and you are confident of safety).
Once the rim is removed, the edges of the resulting bowl will be sharp and dangerous. They must be processed. Use a sweeping circle on a Bulgarian or even a petal disc to remove the chamfer and round the edge. This will not only protect your hands from cuts in the future, but also improve the adhesion of paint in this area. Some craftsmen prefer to leave a small side, welding a metal strip so that the coals do not fall asleep in a strong wind, but the classic is the disk It usually has sufficient depth.
The next step is to organize an air supply system. Without good traction, coals will smolder rather than burn, which will ruin the entire cooking process. In the lower part of the bowl, where the central hub hole and fastening holes under the bolts were previously located, it is necessary to drill a number of additional holes with a diameter of 10-15 mm. They should be evenly arranged in a circle and closer to the center of the bottom.
Manufacture of support structure and legs
After forming the bowl, the question will arise before you: how to install the grill? There are two main ways: the creation of a stationary structure on high legs or the manufacture of a portable version. For comfortable frying of barbecues, the height of the working surface should be approximately 80-90 cm from the ground so that you do not have to constantly bend over.
For the manufacture of legs, most often a profile pipe of square or rectangular section, a corner or even a rebar is used. Metal bars with a diameter of 10-12 mm are also suitable, but they are less resistant to lateral loads. The legs are welded to the outside of the rim (if left) or directly to the side of the bowl. It is important to ensure the symmetry of the installation so that the grill does not stagger.
☑️ Stability control
If you make legs from a pipe, they can be connected to each other at the bottom with additional jumpers. This will give the structure a rigidity and will allow you to install a shelf for firewood or dishes at the bottom. So. bottom-shelf It is very convenient to use, as it allows you to keep a supply of fuel or plates of meat in close proximity to the hearth, but at a safe distance from the heat.
An alternative is to boil into the center of the bottom (from the inside) a segment of the pipe, which will serve as a stand. In this case, the grille can simply be put on the ground, paving stones or a special platform. This option is good for mobility, but less convenient for long-term cooking due to the low planting.
Welding and structural reinforcement
Welding is a key step in determining the durability of your product. As the grill will undergo cyclic heating and cooling, welds experience significant thermal stresses. Use electrodes with rutile or basic coating that provide a plastic seam. Before welding, be sure to clean the joints to pure metal, removing all rust, oil and paint residues.
When cooking legs to the disc, try to make seams in a circle, providing the maximum contact area. If the legs are thin and the disc wall is thick, the metal can burn quickly. In such cases, it is recommended to cook with short seams (articks) in a circle, allowing the metal to cool down to avoid warping the structure. Thermal deformation The main enemy in the collection