What can I make grill grates out of?

Grill grates are an essential part of any barbecue setup – they hold the food above the heat source and allow grease and juices to drip away. While stainless steel grates are the most common, there are many DIY options for creating grates out of materials you may already have around the house. With some simple tools and basic construction skills, you can fashion sturdy, safe grates from inexpensive items like rebar or galvanized steel. Read on to learn about the pros, cons and best practices for using various metals and alloys to make your own custom grill grates!

Quick Answers

Some common materials used for DIY grill grates include:

• Stainless steel – Durable, conducts heat well, won’t rust.
• Cast iron – Holds heat well, but can rust over time.
• Aluminum – Lightweight and inexpensive, but melts at high temperatures.
• Steel rebar – Sturdy and inexpensive, but can rust if not properly coated.
• Expanded metal – Allows more airflow and drainage, but thinner than solid grates.

Key factors to consider are durability, corrosion resistance, heat conduction, weight, and cost. Stainless steel is ideal, but materials like rebar and galvanized steel can work well with proper maintenance.

Stainless Steel

Stainless steel is one of the best materials for grill grates. It is durable, resistant to rust, conducts heat evenly, and withstands high temperatures. Stainless steel grates are easy to clean and maintain their shiny appearance over many seasons of use.

There are a few ways to make DIY stainless steel grates:

• Purchase stainless steel rods or bars and cut them to size with a hacksaw. Drill holes and use stainless steel bolts to connect them into a grate shape.
• Use a welding machine to join pieces of stainless sheet metal or bar stock into a grate pattern.
• Buy a prefabricated stainless steel expanded metal sheet and cut it to size with tin snips or a plasma cutter.

Pros:

• Extremely durable and long-lasting.
• Resists rust and corrosion.
• Conducts heat evenly for consistent grilling.
• Easy to clean and maintain.

Cons:

• More expensive than other DIY grate materials.
• Welding or metal fabrication tools needed to construct grates.

Stainless steel is one of the best choices for grill grates you want to last a lifetime. With some DIY metalworking skills, you can create custom stainless grates tailored exactly to your grill size and shape.

Cast Iron

Cast iron is another excellent choice for homemade grates. While it can rust if left exposed to the elements, properly cared for cast iron grill grates will provide top-notch grilling performance for years.

Cast iron conducts heat evenly, retains heat well, and develops a natural non-stick surface over time. Here are some cast iron grate options:

• Use multiple cast iron pans or skillets placed side by side.
• Look for old cast iron grates at flea markets or garage sales.
• Cut a cast iron pan into sections and reconnect them into a grate pattern.
• Make a mold and pour molten cast iron into it to form the grate shape.

Pros:

• Excellent heat conduction and retention.
• Naturally non-stick when seasoned properly.
• Can reuse vintage cast iron pieces.
• Doesn’t require metalworking skills.

Cons:

• Prone to rusting, requires seasoning and maintenance.
• Very heavy.
• Brittle if cooled rapidly.

With proper use and care, cast iron makes for a heavy duty and high performing backyard grill grate. It’s a great option if you can find used cast iron cookware to repurpose.

Aluminum

Aluminum is lightweight, inexpensive, and easy to work with. But it has a low melting point that makes it unsuitable for very high temperature grilling. With some precautions, aluminum can be formed into grill grates:

• Cut aluminum angle iron into grate sized pieces and bolt them together.
• Use an aluminum welding machine to join aluminum bar or sheet stock.
• Cut aluminum pipes into short lengths and space them apart for a grated surface.

Pros:

• Very lightweight.
• Inexpensive and widely available.
• Easy to cut and work with using common tools.

Cons:

• Melts at around 1,200°F – too low for very hot grilling.
• Doesn’t retain heat well.
• Can warp or sag over time.

Aluminum is okay for low-temperature grilling up to around 400°F. But it shouldn’t be used over a very hot open flame or for searing. It melts too easily. Stick with aluminum for mildly heated barbecue smoking.

Steel Rebar

Steel rebar is an inexpensive, readily available material for making sturdy DIY grill grates. You can often find it salvaged from construction sites.

To make rebar grates:

• Cut the rebar to equal lengths with a metal chop saw or hacksaw.
• Space and arrange the pieces evenly and bolt them together.
• Use rebar tying wire to wrap and secure points of intersection.

Pros:

• Low cost and easy to find.
• Very sturdy and durable construction.
• Easy to work with simple tools.
• Conducts heat evenly.

Cons:

• Prone to rusting – needs high temperature paint.
• Not as attractive as stainless steel.
• Can have rough edges.

To prevent rusting, scrub the rebar with sandpaper, wipe it down with acetone, and apply multiple coats of high heat grill paint. With proper rust protection, steel rebar makes very rugged and affordable grill grates.

Galvanized Steel

Galvanized steel is regular carbon steel or iron that has been coated with a layer of zinc to prevent rusting. This makes it suitable for DIY grill grates, while costing less than stainless steel.

You can work with galvanized steel the same ways as rebar:

• Cut galvanized round bar or angle iron to length with metal shears or a chop saw.
• Arrange and bolt or wire the pieces together into a grate pattern.

Pros:

• More rust resistant than regular steel.
• Harder and more durable than aluminum.
• Lower cost than stainless steel.
• Readily available at hardware stores.

Cons:

• Coating can wear off over time.
• Not as corrosion resistant as stainless.
• Can leach toxic zinc oxide at very high temps.

Galvanized steel is a decent budget option for grill grates if properly maintained. Re-coat with high temp paint periodically to prevent rusting. Avoid flaking of the zinc coating into food by not using it at extremely high temperatures above 700°F or so.

Expanded Metal

Expanded metal is made by cutting a grid pattern into sheet metal and stretching it to form diamond shaped openings. This lets heat, grease, and smoke pass through easily. It can be used for grill grates with some modifications:

• Purchase thicker gauge expanded metal, at least 16 gauge.
• Cut sections to size and use angle iron pieces to frame and reinforce the grate.
• Consider adding thinner solid rods between wider openings for support.

Pros:

• Enables maximum airflow and smoke transfer.
• Allows grease drainage.
• Can see and access fire beneath the grate.

Cons:

• Thinner than solid rod grates.
• Food can slip through larger openings.
• Harder to clean all the crevices thoroughly.

With some modifications for strength and stability, expanded metal can make excellent grates for smoking foods low and slow or for grills designed to infuse maximum flavor.

Choosing the Right Metal

When selecting a material for DIY grill grates, consider these key factors:

• Durability – Will it resist corrosion and withstand high temperatures?
• Heat conductivity – Does it transfer heat evenly for consistent grilling?
• Weight – Will the grates be easy to handle and maneuver?
• Cost – What fits your budget? How readily available is the material?
• Ease of use – Can you work with the material to fabricate grates?

Stainless steel is ideal in terms of durability, conductivity, appearance, and ease of maintenance. But rebar, galvanized steel, aluminum, and cast iron can also perform well. Avoid thin, mild steel that will rust through quickly. Focus on metals that conduct heat evenly and won’t melt or warp under high temperatures.

Designing DIY Grill Grates

Keep these tips in mind when designing and fabricating your own grill grates:

• Match the dimensions of your existing grill’s lid and flame area.
• Space rods or wires evenly apart for stability.
• Use heavier gauge metal for better durability.
• Allow for airflow gaps between pieces.
• Use sturdy corner joints and tie points.
• Coat with high heat resistant paint if needed.

Measure carefully so the grates fit properly in your grill housing. Allow a gap of at least 1/8 inch between pieces to avoid hot spots. Wire brush and prep metal before coating with a high temperature resistant paint.

Focus on sturdy construction and even spacing between rods or wires in the grate pattern. This allows heat to transfer evenly across the grilling surface for the best results.

Safety Tips

When cooking over DIY grill grates, keep these safety tips in mind:

• Use caution when handling hot grates to avoid burns.
• Don’t exceed the safe cooking temperature of the metal used.
• Watch for wear over time and replace as needed.
• Keep a spray bottle with water handy to control flare ups.
• Ensure grates are totally cool before inspecting or storing grill.

It’s also important your grill body and frame are sturdy enough to safely hold the weight of the grates and food. Make sure the new grates don’t throw off the balance or stability of your grill when loaded up.

Maintenance

DIY metal grill grates require proper maintenance for best performance:

• Seasoning – Season cast iron grates by lightly oiling and heating to prevent rust.
• Remove residue – Thoroughly brush and scrape grates clean after each use.
• Re-coat – Reapply high heat paint periodically to prevent rusting.
• Inspect for damage – Watch for cracking or deterioration and replace as needed.

Take time after each grilling session to clean the grates fully while still warm. Regularly check for any wear and tear or rust spots and touch up with fresh paint as required. Proper maintenance will keep homemade grates in peak grilling shape for many barbecue seasons.

Conclusion

Crafting DIY grill grates allows you to customize your barbecue setup on a budget. With some basic metalworking skills and appropriate materials like stainless steel, rebar, or galvanized iron, you can fashion sturdy grates tailored to your specific grill. Maintain your homemade grates by conducting regular inspections, promptly removing grime after each use, and re-coating with fresh paint periodically to get the most value from your creation. Feel free to get creative with grate patterns and materials – building your own grates can be a fun and fulfilling backyard DIY project!