How do you build a grill over a fire pit?

Building a grill over a fire pit allows you to cook food with the smoky flavor of an open fire while still having a grill surface to place your food on. This can be a fun backyard project that results in a unique cooking setup. There are a few key considerations when putting together a DIY grill over a fire pit.

Choosing a Location

First, you’ll need to pick out a good spot to install your grill. Here are some tips for choosing a location:

• Select a level, flat area of ground near your existing fire pit.
• Make sure there is adequate space around the grill for access and safety.
• Consider wind patterns so smoke does not blow directly toward your house/deck.
• Check for overhead obstructions like tree branches.
• Pick a location at least 10 feet away from any structures or combustible materials.

You’ll need about a 6-8 foot diameter clear area to accommodate the grill and work space around it. Positioning the grill close to your fire pit will make it easier to shift coals underneath.

Constructing the Grill

Once you’ve identified the right spot, you can start building the grill. There are a variety of methods and designs you can use. Some key steps include:

1. Make a frame – This provides support for the grill. Use metal pipes, heavy duty wire mesh, cinder blocks, bricks, or stones. Shape into a square, rectangle or circle over the fire pit.
2. Add legs – Legs raise the grill surface above the fire pit. Use metal poles or masonry materials about 5-6 inches tall. Angle legs slightly outward for stability.
3. Install wire mesh – Cut heavy duty wire mesh (steel or iron) to lay across the frame as a grate. Secure with metal clips, ties or welding.
4. Consider an optional pan – For easier ash removal, place a steel pan (like a baking sheet) with drainage holes under the mesh grate.

Be sure the grill is high enough above the fire pit to allow ventilation and ash drainage. The frame should be sturdy and anchored securely in the ground.

Grill Building Materials

Some of the common materials used for constructing grills over fire pits include:

Material	Pros	Cons
Steel pipe or tube	Very sturdy, high heat resistance, long lasting	Can be expensive, requires welding
Iron wire mesh	Inexpensive, easy to work with, good ventilation	Can rust over time
Stainless steel	Exceptional durability, weather resistance, attractibe appearance	Higher cost, requires metalworking tools
Cinder blocks	Cheap, readily available	Prone to cracking, not as sturdy

Grill Cooking Surface

The cooking surface is one of the most important choices you’ll make in designing your DIY grill. Here are some popular options:

• Steel wire mesh – This is one of the simplest cooking surfaces. Sturdy wire mesh lasts for years and is easy to shape and handle. Be sure to choose steel or iron mesh rated for high heat.
• Expanded metal – Expanded metal sheets provide excellent ventilation and a nice cook surface. This material is comfortable to work with using basic metal snips and pliers.
• Iron grates – Using scrap iron or steel grates like those from an old oven provides a time-tested cooking surface that’s easy to maintain. You may need to weld sections together.
• Steel rods – Arrange steel rods in a grid pattern and weld in place for a custom cooking grill. Stainless steel rods offer great longevity.

Aim for a cooking surface at least 18-24 inches square to provide adequate space for food. Be sure to leave small gaps between grid pieces to allow ash drainage.

Comparison of Grill Cooking Surfaces

Surface	Durability	Ease of Installation	Cost
Wire Mesh	Good	Easy	Cheap
Expanded Metal	Very Good	Intermediate	Medium
Iron Grates	Excellent	Difficult	Cheap to Medium
Steel Rods	Excellent	Difficult	Expensive

Safety Tips

Safety should always be the top priority when dealing with open flames. Here are some important safety precautions to take with your DIY grill:

• Keep the grill at least 10 feet away from any structures, trees or shrubs.
• Do not use lighter fluid or other accelerants as they can create flashbacks.
• Have a fire extinguisher and/or water bucket nearby in case of emergencies.
• Do not leave the fire unattended and make sure it is completely extinguished when finished.
• Watch for hot embers or ash falling from the grill.
• Wear protective gloves and use long cooking tools to avoid burns.
• Do not overload the grill with too much food or pile up coals excessively.
• Remove any decorations or ornaments attached to the grill before lighting the fire.

Proper site selection, construction, operation and supervision will help make your DIY grill a safe, fun backyard addition.

Operation Tips

Once your grill is built, here are some tips for great results:

• Use seasoned hardwoods like oak, hickory or mesquite for the best flavor.
• Let the fire burn down to hot coals before cooking.
• Brush or spray oil on the cooking surface to prevent sticking.
• Sear foods first to lock in juices before moving to indirect heat.
• Add smoker boxes of wood chips/chunks to infuse more flavor.
• Flip foods frequently and move around the grill surface for even cooking.
• Keep a stock of dry wood nearby to maintain your fire.
• Consider cooking low and slow for tender BBQ meats.
• Use a meat thermometer to ensure foods are cooked to safe temperatures.

With some practice you’ll be an expert outdoor chef in no time!

Maintenance

Like any outdoor appliance, your DIY grill will require occasional maintenance. Follow these tips to keep it in top shape:

• Periodically check for cracks or damage, especially if using masonry materials.
• Remove cooking grates and clear any debris or excess ash from the pit.
• Use a wire brush to remove grime buildup on grill grates.
• Replace severely rusted or broken parts like pipes or grates.
• Apply high heat paint if needed to refresh and protect the grill frame.
• Wipe down exterior surfaces to remove food drippings and other residue.
• Consider covering the grill when not in use to extend its life.

With regular upkeep and care, a quality DIY grill can easily last 5+ years outside!

Conclusion

Installing a grill over your backyard fire pit creates a fun, unique cooking space to enjoy smoky flavors. The key steps are choosing a safe location, building a sturdy support frame, selecting good cooking grates, and following safety precautions. Using quality materials and regularly maintaining your DIY grill will ensure it withstands the elements and provides top performance for years of barbecue cooking.