Manufacture disk-plate It starts with the exact marking of cutting lines on stamped steel, since the wrong angle of the cut will lead to deformation of the side when heated. R15 and R16 discs are most often used to create stationary roasters under the Kazan, since their diameter perfectly coincides with the seat of standard pilaf dishes. The thickness of steel in car discs is 3-5 mm, which guarantees the durability of the structure, but requires the use of a powerful angle grinding tool with diamond or metal alloy circles. Before starting work, it is necessary to thoroughly clean the surface of old paint and rubber residues to exclude the release of toxic substances during the first ignition.
The process of transformation of the wheel into a focus requires compliance with safety precautions, since work with the wheel is not necessary. Bulgarian And the welding machine carries the risk of injury. The inner part of the disk often has complex geometry to consider when designing. blown for air supply. If you plan to use the design not only for barbecue, but also as a barbecue oven, it is worth pre-provisioning a place for installing grilles or skewers. Ready. disk-plate It has excellent heat capacity, allowing you to keep the heat for a long time for evenly frying meat.
⚠️ Note: It is strictly forbidden to cut discs that have previously been subjected to heavy heating or had cracks, since the structure of the metal could be disturbed, which will lead to rapid burnout of the walls.
Selection of suitable discs and preparation of metal
The best material for creating brazier are steel stamped discs, as they are easier to weld and process than light alloy analogues. Cast aluminum discs require a special approach to welding in an inert gas environment, which is difficult to implement in a garage without special equipment. The diameter of the product directly affects the functionality: a disk is ideal for installing a pot with a volume of up to 20 liters. R15 or R16For large companies, it is better to look for a basis. R17 and higher. It is important to make sure that there is no deep corrosion, through holes or repair marks on the metal, which can become foci of destruction during cyclic heating.
Surface preparation involves removing all non-metallic elements, including balancing loaders and tire residues. Use of the diaphragm allows you to remove a layer of paint to pure metal, which is critical for the quality of the weld. If you use composite discs where the central part is welded to the rim, it is necessary to check the integrity of the factory seam, since under thermal load it can not withstand. For decorative elements, the central part of cast discs is often used, cutting out patterns from them, but the bearing structure is better made of thick stamping.
- 🔍 Check the thickness of the disc wall with a rod – it should be at least 3 mm for long service.
- 🔥 Make sure the metal has no traces of heat treatment or hardening that can cause fragility.
- 🛠️ Prepare the tools in advance: a Bulgarian with a reserve of circles, a welding machine and protective equipment.
- 🧹 Carefully clean the inner cavity of dirt, oils and bitumen stains before cutting.
To facilitate cleaning of the disc from the paint, you can preheat it with a burner, after which the old layer is easily cleaned with a metal brush.
Required tools and materials for assembly
Assembly grill It's impossible without quality. welding-equipmentpreferably a semi-automatic, which provides a smooth and durable seam on a thin metal. For cutting workpieces will require a corner grinding machine with metal discs with a thickness of 1.0-1.6 mm, which will make accurate cuttings without excessive material consumption. If the design involves the installation of doors or adjustable air supply, you will need sheet metal 2-3 mm thick for the manufacture of flaps and blown. Additionally, you should stock up on heat-resistant paint for external surfaces, which withstands temperatures up to 600-800 degrees Celsius.
As additional materials, rebars or corners are often used to create legs and a frame if the cladding is not mounted in the finished support structure. For the installation of the casing (may be required) metal bar diameter of 8-10 mm, from which the ring-holder is cooked. All connecting elements, such as bolts and nuts for fastening handles or doors, must be made of heat-resistant alloys so as not to cling or deform. Presence metalbrush And a degreasing agent is necessary for finishing the surface before painting.
| Material/Tool | Appointment | Requirements |
|---|---|---|
| Disc R15-R17 | The base of the roasting | Steel, no cracks |
| Bulgarian (USM) | Metal cutting | Power from 2,000 watts |
| Welding machine | Connecting parts | Semi-automatic (MIG/MAG) |
| Heat-resistant paint | Protection of the hull | Up to 800°C, black. |
| Rebar d12-16 | Feet and frame | Riffled surface |
⚠️ Warning: Always use protective glasses and gloves when working with a Bulgarian, as sparks and metal shavings can cause serious burns and eye injuries.
Step-by-step instruction: cutting and forming the bowl
The first stage of creation grill is an accurate marking of the line of the cut of the disk. Usually retreat 10-15 cm from the upper edge to form a deep bowl, sufficient for stacking firewood and placing skewers at the desired height. Cut the metal should be strictly along the intended line, trying to guide the tool evenly to avoid distortions, which will then be difficult to correct. If you do disk-plate with a door for scavenging ash, at this stage mark and cut a hole in the lower part of the board.
After splitting the disc into two parts (upper and lower), it is necessary to treat the edges of the cut, removing the burrs and leveling the cut line. The bottom part that will become the bowl often requires the installation of additional hardness ribs or bottom if the regular bottom of the disc is too thin or has large bolt holes. The top can be used to create a cover or decorative elements, which will turn a simple brazier into a closed one. smoke-box. It is important to keep the central opening of the disc, as it provides natural traction and air access to the coals.
☑️ Cutting and preparation stages
The formation of the combustion zone requires the removal of the central protrusion ( hub) in some models of disks, if it interferes with the uniform distribution of coals. Sometimes masters weld a metal mesh or strawberries inside the bowl to lift the coals above the bottom and ensure a better supply of oxygen. This modernization makes it simple. metallic a vessel in an effective oven where the ash does not interfere with the heat. To install the casing, the upper section of the side should be perfectly smooth, so it is often reinforced with a strip of metal or fittings.
The main advantage of using a car disc is the ready-made round shape and the optimal metal thickness, which does not require complex flexibility.
Welding of the frame, legs and additional elements
Assembly of the bearing structure begins with welding the legs to the main bowl, for which usually use a rebar or profile pipe with a cross section of 20x20 mm. The height of the legs is calculated individually, but the standard distance is 80-90 cm from the ground to the upper edge of the grill, which is convenient for standing cooking. So mantle was stable, the legs are placed to a width exceeding the diameter of the disk, and connect them at the bottom with jumpers, which also serve as a shelf for storing firewood or dishes. Welded seams must be cleaned with a grinding wheel so that they do not spoil the appearance and do not interfere with the application of the coating.
If the project provides for the presence of a blowing door, it is cut from the remaining part of the side or a separate sheet of metal, fixing it on hinges. To adjust the thrust in the door, several holes are drilled or a sliver valve is installed, which allows you to control the intensity of firewood. Pens for carrying the cuff and opening the doors should be reliably welded and, preferably, have a wooden or heat-resistant plastic lining, so as not to burn the hands. In some designs, wheels from a garden trolley are welded to the legs for mobility, which is important for heavy models from cargo disks.
- 🔨 Weld the legs to a reinforced ring, rather than directly to the thin side, to avoid tearing off under the weight of the structure.
- 🌬️ Leave gaps or drill holes in the bottom of the bowl to ensure the air is naturally drawn.
- 🍳 For the version under the Kazan, weld three stops from the rebar inside the rim so that the vessel does not fail.
- 🎨 All welded joints must be cleaned and defatted before the final painting with a heat-resistant composition.
Additional items, such as skewer hooks, spice shelves or towel holders, are welded at the final assembly stage. Use of the forged It can give a homemade grill the appearance of an expensive factory product. It is important to check the geometry of the assembled structure on a flat surface: the cladding should not stagger, and all flat surfaces (shelves, countertops) should be strictly horizontal. If installation is planned chimney for use as a smoker, the pipe is mounted on the back wall or side, providing a removable cover.
The Secrets of Sustainability
To increase stability on uneven ground to the ends of the legs, you can weld triangular pads-petaks, which will increase the area of the support and prevent the grill from being pressed into the ground.
Surface treatment and finishing
Protection metal corrosion and high temperatures is a critical stage that determines the service life of the product. Ordinary enamel will quickly burn out and begin to peel at the first ignition, so it is necessary to use specialized heat-resistant paints on a silica-based. Before painting, the surface is thoroughly degreased with a solvent to ensure maximum adhesion of the coating. It is better to apply paint in 2-3 thin layers with intermediate drying, following the instructions on a can or can.
An alternative to painting is the rotting or oxidation of metal, which creates a strong black oxide film on the surface. This method is more time-consuming and requires the use of chemical reagents or calcination with oil, but the result is more durable and natural. The easiest way to primary processing is to calcinate the mangal with vegetable oil.By filling the bowl and warming it up, which creates a primary protective layer of polymerized fat. Decorative forging or slathering patterns can also serve as protection, closing the base metal from direct contact with fire.
⚠️ Warning: Never use the grill immediately after painting, let the coating dry completely and polymerize, otherwise the food may absorb the smell of chemicals.
Operation, care and security measures
Proper operation grill It extends its life and ensures the safety of cooking. The first ignition is recommended to be carried out out outdoors away from flammable objects to burn out the remnants of factory lubrication, paint and possible contamination. Do not pour water on hot coals to extinguish them, since a sharp temperature difference can lead to deformation of the thin metal of the disc and cracking of welds. Zou from the grill is removed only after the complete cooling of the structure, pouring it into a metal container.
Regular care consists of periodic cleaning of the coar with a metal brush and updating the protective coating as needed. If mantle used under the cauldron, it is important to ensure that the fat flowing from the dishes does not accumulate on the walls and bottom, creating a fire-hazardous situation. Store the product better under a canopy or in a dry room, covering with a cover to prevent corrosion from precipitation. When through corrosion appears in certain places, they can be brewed or closed with metal linings.
Compliance with safety measures when using fire-fire It is a prerequisite. Do not leave a burning grill unattended, especially if there are children or pets nearby. Make sure that the structure is installed on a non-combustible base (tiles, concrete, sand) and is located at a sufficient distance from wooden buildings and trees. Windy weather requires installation of windscreens or transfer of the brazier to a more protected place.
To skew skewers do not turn and do not fall into the grill, make small notches or weld stops on the top side of the disk.
Can I use cast discs for a grill?
You can use cast discs, but it is more difficult. Aluminum has less heat resistance and can melt or deform when heated, and aluminum welding requires argon and skills. It is better to use them as a decorative element or a base for lightweight structures without exposing them to extreme temperatures.
Which disc is better to choose: R14, R15 or R16?
The best choice is the R15 or R16 disk. R14 may be a bit small for a large company, and R17 and higher are already too heavy and deep. R15/R16 is ideal for standard cauldrons and provides a good height for skewers.
Do I need to make air holes in the bottom?
Yeah, holes are necessary for traction. However, in car drives, the central opening often already provides sufficient inflow. If the clasp is deep, you can drill a number of holes in a circle at the bottom of the bowl.
How do I paint the grill inside?
Inside the grille can not be painted with ordinary paints. The best option is to calcinate with oil (sweeping) or leave without coating, regularly cleaning from the sodium. Special heat-resistant paints for furnaces (up to 1000 ° C) are also suitable for the interior.
How do you make a curtain mobile?
For mobility to the legs of the curtain welded two wheels from the garden cart or bicycle. On the opposite side, a handle is made for tilting and transportation. It is important to consider the weight of the structure with wood.