Prepare the Barrel

• 1). Don wrap-around eye protection, ear protection and a NIOSH-approved respirator.
  
  
• 2). Cut a 1/4-section from the barrel along its length, using a cutoff wheel on a right-angle grinder.
  
  
• 3). Use a 24-grit grinding wheel on a right-angle grinder to deburr all cut edges of the barrel and the 1/4-section you removed. Repeat with an 80-grit flapper wheel.
  
  
• 4). Cut two pieces of 1-inch by 1/8-inch steel bar stock to the same length as the barrel height. Cut two more pieces to the same length as the barrel diameter.
  
  
• 5). Don your welding helmet, gloves and full leathers. Position the four pieces of steel bar stock on their 1/8-inch edges and weld them into a rectangular frame.
  
  
• 6). Lay the barrel on its side so that the cut-open portion is facing you, with one cut edge horizontal and one vertical. Position the rectangular frame so that it fits around the barrel, centered along the horizontal cut-line. Weld the frame in place.
  
  

Create the Barrel Support Frame

• 1). Cut two pieces of 2-inch by 1/8-inch steel bar stock to the same length as half the circumference of the barrel, minus 1 inch. Bend both pieces to fit the curve of the barrel as closely as possible, heating them with a torch if necessary.
  
  
• 2). Cut two pieces of 2-inch by 2-inch angle iron to the same length as the barrel height, and two pieces to the same length as the barrel diameter. Miter each end to a 45-degree angle.
  
  
• 3). Lay the four pieces of angle iron in a rectangle with the mitered edges together, with one leg of each piece pointing toward the center of the rectangle and one leg pointing toward the ceiling. Weld the pieces together along the mitered seams to create the barrel support frame.
  
  
• 4). Cut four pieces of angle iron 36 inches long. Position one of the 36-inch-long pieces of angle iron vertically in each corner and weld them in place to create the legs for your barrel support frame.
  
  
• 5). Turn the barrel support frame right-side up. Position the barrel on top of it, with the ends of the barrel flush with the ends of the frame. Lift the barrel slightly and position the curved pieces of bar stock under it, at each end of the frame.
  
  
• 6). Adjust the curved supports until each end meets the 1-inch frame around the barrel. Weld the curves to the frame around the barrel and to the barrel support frame underneath.
  
  
• 7). Grind all welds smooth using a 24-grit and 80-grit wheel on your right-angle grinder.
  
  
• 8). Have a helper hold the 1/4-section you removed from the barrel in place while you mark positions for the hinges. Weld the hinges to the 1/4-section and the barrel to create your grill hood.
  
  
• 9). Center the 6-inch-long, 2-inch-deep wooden-handled steel drawer pull on the front of the grill hood and weld it in place.
  
  
• 10
  
  Cut 2-inch angle iron to the length and width of the inside of the barrel. Miter the ends to 45-degree angles and weld the pieces together to form a grill frame. Cut expanded-steel mesh to fit the grill frame and weld it in place. Turn the grill frame over and weld it inside the barrel.