I just finished reading literally this entire thread... OK, I skimmed a bit... But yeah.
I realize there are good commercial option out there... but this thread seemed to have died so abruptly for what seems to be such an awesome budget build.
Hopefully its not bad form to bump this, but I can't help but think it should keep going?
Cost so far was about $35 but I am going to add a kiln shelf so that may double the cost?
It uses a Baja Classic SP10 burner with 10psi regulator I need for brewing anyways.
The BBQ was new from walmart, It is currently $20 brand new for the 17.5 square grill.
It uses a stainless steel serving dish I got from a restaurant supply company for $10
And 2 12in quarry tiles that I got for free as sample (I tried to buy them... Told them I only needed a few... They gave me 2 different colors and said sample are free. If you need tile they seem to be good people over at tile 4less
- I cut the grill to fit over the burner, same diameter as the ring on the burner ~10in
- I left 3 square tabs sticking inwards from this cut, evenly spaced around the circumference, and folded them down to lock the grill onto the burner. The tabs fit tightly between the supports the grill sits on. Easy to remove but wont move around with out being lifted up.
-I cut the serving tray to fit on the lip of the bottom half of the grill, where the normal cooking grate sits, then hammered the sides flat to make it wider... This made it ~17.5X15in. I traced the corners of the grill and rounded two corners of the sheet created by the tray so that it would slide to the front of the grill.
-I put the grate on top of the stainless steel sheet, and put the tiles on top of the grate.
-I used the end cut off of the serving tray as an upper air deflector. No false ceiling was needed in the lid, as this grill is very squat, and the defector sits with very little clearance above a cooked pie (I tested this ahead of time by loosely balling tinfoil, then smashing it down with the lid... This leave the tinfoil in the shape of the open area to show you what your working with)
The aluminum tray shown was not used, I had planned to make a ceiling out of it.