Build Your Own DIY BBQ Grill Station with This Handy Tutorial

Not only is this DIY BBQ station easy on the eyes, but it also cooks just like a chef.
Christopher McFadden

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Everyone loves to barbeque, but sometimes charcoal, or wood, cooking just doesn't cut it. This is where gas-fired grills really come into their own. 

But, instead of buying a standalone unit, why not integrate one into t a custom-built unit?  

Important note: Please note the following project requires a connection to the gas mains. It is highly recommended you hire the services of a professional gas engineer to complete those steps for you. Under no circumstances should you work on gas lines yourself if you have no experience or knowledge of doing so!

diy grill complete
Source: Interesting Engineering/YouTube

Like any project of this nature, you will need some tools and materials before starting. 

If you want to replicate this product exactly, you will need to order a custom outdoor grilling station as supplied by companies like Grillnetics. Alternatively, you could attempt to design one yourself and buy the necessary framing and other components required. 

With either of those steps complete, now it is time to get on with the build. 

Follow the instructions to construct the station as required. The kit, if bough off-the-shelf, should come with all the necessary nuts, bolts, and basic tools required. 

outdoor grill station assemble
Source: Interesting Engineering/YouTube

The kit may also come with leveling feet, but you can leave that for now until later in the build. Depending on the design, and the kit in question, you may need to use construction adhesive, like Locktite, for certain elements. 

Otherwise, use wrenches and power tools to bolt together the steel frame and boxing boards as needed. This kit comes with the required cementboards and steel framing components needed. 

diy grill assembly
Source: Interesting Engineering/YouTube

Throughout the construction, ensure that all components and modules of the outdoor grill are level and flush when secured together. This will be critical for future use of the grill, and the final aesthetics of it. 

diy grill flush and level
Source: Interesting Engineering/YouTube

With all modules complete, and attached together, you can now take the time to ensure they are all level. Adjust each of the leveling feet as needed to achieve this. 

Make good use of spirit levels, obviously. 

outdoor grill level
Source: Interesting Engineering/YouTube

Next, it is time to make room for your grill. Some models will come with detailed instructions on how to fit them, others not. 

Remember, whenever cutting construction materials, like insulation board, always do it in a well-ventilated space and wear appropriate respiratory protective equipment!

Either way, mark out the dimensions of the grill to your completed outdoor grill frame. Cut out the space needed to fit the grill into the frame, if needed. 

outdoor grill cut to shape
Source: Interesting Engineering/YouTube

As always, measure twice, cut once! It will save you a massive headache later down the line. Next, install, if needed, the grill supports bars to the main DIY cabinet. 

Ensure this is securely fastened and attached to the rest of the frame as this will be the only thing supporting the weight of the grill (and the food when in use).

You don't want the grill falling under its own weight -- especially when in use. That would be annoying and potentially very dangerous!

outdoor diy grill supports
Source: Interesting Engineering/YouTube

Next, you can begin to install the countertop. For this build, a 12.7 mm (1/2 inch) cement board was used. Adhere to the frame using construction adhesive and leave to set. 

outdoor grill countertop
Source: Interesting Engineering/YouTube

With that installed, mark out the space needed to install the grill. Again measure twice and cut once!

diy grill counter 1
Source: Interesting Engineering/YouTube

Once you are happy, now it is time to cut out the pieces in the countertop and side paneling as needed to fit the grill. You can use an angle grinder with a suitable cutting blade (like a diamond-tipped one) as needed.

diy outdoor grill cut
Source: Interesting Engineering/YouTube

Make sure you take the necessary precautions and wear safety gloves, and other PPE and RPE. Now cut to size, as needed, adhere, and screw the rest of your countertops to the rest of the frame. 

diy outdoor grill tops
Source: Interesting Engineering/YouTube

Now, and if required, mark the location of any cabinets you require for the outdoor grill station. Carefully measure, and mark out the dimensions needed to cut through the side paneling. 

diy grill cabinets
Source: Interesting Engineering/YouTube

Once happy, cut out as before with the countertops. For best results, line the opening with steel rails for added strength and durability. 

Next, tape over any joints between the boards with cement board tape (or mesh tape) on the vertical surface of the grill. This will ensure the Ardex OVP (or similar product) doesn't crack along them in the future. 

diy grill tape
Source: Interesting Engineering/YouTube

With that complete, mix up your Ardex OVP as instructed. Once ready to the required consistency, begin to trowel and smooth over the exterior vertical surfaces of the DIY grill. 

Take your time, and ensure the surfaces are smooth and flat (if desired). Alternatively, you can finish to whatever texture you like. Plastering is a very skilled profession in its own right, so do the best you can. 

diy grill external plastering
Source: Interesting Engineering/YouTube

Once complete, allow the product to cure as needed before moving on to any of the next steps. If desired, add any epoxy surfacing product to the countertop, or real-stone countertops. 

Once complete, you can begin to install the cabinets, as needed. 

Maneuver the cabinets into place and secure them to the frame as needed. If your measurements were spot on from before, they should slide smoothly into place. 

Adjust as needed otherwise. 

diy grill install cabinets
Source: Interesting Engineering/YouTube

With the cabinets installed, and firmly secured to the main steel frame, it is time to begin completing some of the finer aesthetic finishes to your grill -- like any trims.

Measure and cut to size, apply adhesive, and then screw to the main steel frame as desired. You don't need to do this, but the creator of this grill wanted to hide the leveling feet from view. 

diy grill trim
Source: Interesting Engineering/YouTube

Once installed, caulk any gaps and remove any protective coating (especially if you plan on painting it later). 

diy grill caulking
Source: Interesting Engineering/YouTube

If required, mark out and install any ventilation grills/vents needed for the main grill unit. As always ensure you measure twice and cut once, and ensure it is level. 

diy grill ventillation
Source: Interesting Engineering/YouTube

With that complete, you can now begin to paint (if desired) all vertical surfaces of the outdoor grill unit. Use masking tape to cover over any areas you don't want painted (like the cabinet units). 

diy grill paint
Source: Interesting Engineering/YouTube

Depending on the product chosen (ensure it is for outdoor use), you may need 1-2 coats for full coverage. Once the paint is dry, go round the entire unit and caulk and, and all, remaining seams (like around the cabinet units). 

Remove any masking tape you placed prior to painting. 

diy grill paint and caulk
Source: Interesting Engineering/YouTube

Fit any other features, like the grill vent, if not already installed. 

Now it is time to connect up any gas lines needed. If required, cut a hole in the side of the unit nearest a gas line and grab any gas piping needed to install to the grill unit.

If you plan on using gas bottles, setup and install as needed inside the cabinet. Gas is highly flammable (and noxious) so ensure you take all the necessary safety steps, as required. 

Depending on the grill chosen, and gas line, you may need to adapt any gas lines and piping to fit. Ensure all parts fit snuggly and airtight. 

Take your time to ensure this is the case. Alternatively, hire the services of a qualified gas engineer to do this all for you. 

diy grill gas lines
Source: Interesting Engineering/YouTube

Run the gas pipes from the mains (or bottles) into place within the cabinet just underneath the grill unit. 

Next, get a helping hand, lift and install the actual grill unit to the cabinet. Take your time and adjust as needed.

diy grill install
Source: Interesting Engineering/YouTube

Install and connect any electrical fitting at this stage too. Prior to testing the grill, unless already done so by a gas engineer, check the gas lines for any leaks. 

You can use some soapy water and a spray bottle for this purpose. Any leaks can be detected by observing any bubbles forming in the soapy spray.

If you see any, turn off the gas, and tighten any fittings.