Make the Grill Box

• 1). Don a NIOSH-approved respirator, welding helmet, gloves and full leathers. Have a large, fully-charged ABC fire extinguisher within fingertip reach.
  
  
• 2). Turn your welder to a medium-high or higher setting. Use welding clamps to hold the pieces in position while you fillet-weld the 24-by-12-by-1/8-inch side pieces to the 24-by-18-by-1/8-inch bottom plate. Fillet welds are used to join pieces that meet at right angles.
  
  
• 3). Fillet-weld the 18-by-12-by-1/8-inch side pieces to the bottom plate and to the long sides. This creates an open-topped grill box.
  
  
• 4). Use a cutting torch or plasma torch to make 2-inch-square openings along the bottom edge of each end of the grill box for airflow. Make three equally-spaced openings along the bottom edge of each long side of the grill box as well.
  
  
• 5). Find the center point along the 24-inch edges of your grill box. Fit the 17-3/4 inch long, 1-inch-wide U-channel upside-down between the two long sides of the grill box, centered on that point. The flat bottom of the U-channel should rest 1 inch below the top edge of the grill box, to create a support for your grilling surface.
  
  
• 6). Fillet-weld the U-channel in place at both ends.
  
  
• 7). Fit the angle iron pieces between the sides of the grill box, along each 18-inch side, flush with the top edge of the grill box, so that the base of each "L" points toward the opposite side of the grill box. The side of each "L" should be flush against the right and left sides of the grill box. This creates the right and left rests for your grill top.
  
  
• 8). Lay your two pieces of 1/2-inch-by-24-inch square-rod stock 17 inches apart. Fit the 25 pieces of 1/2-inch-by-16-inch square-rod stock an equal distance apart between the longer rods, with all corners flush. Weld the pieces together to form your grill top.
  
  

Finish and Mount Your Grill

• 1). Turn your grill box upside down. Find the center point on the bottom of your grill box. Center the 3-inch-diameter, 5-foot-long steel pipe on that point and fillet-weld it to the grill box.
  
  
• 2). Dig a 2-foot-deep, 10-inch-diameter post hole in your yard where you want to place your grill. Slip the pipe into the hole and backfill it with sharp-sided gravel.
  
  
• 3). Mix three 80-pound bags of concrete in your wheelbarrow according to package directions, which is the amount recommended by Hoover Fence's concrete calculator. Fill the hole around the steel pipe and allow the concrete to cure for three to five days.
  
  
• 4). Lay your grill top on the grill supports.