Grill Made From a Gas Tank

This instruction manual aims to guide the manufacturing process of a grill made from a gas tank, using common metal materials and basic workshop tools such as a welding machine and an angle grinder. Throughout this document, the main steps for assembling the structure, installing components, and applying final finishes are described.

This project is designed so the user can adapt the measurements and proportions according to their needs, while always maintaining functionality, stability, and safety. It is important to carefully follow each step and respect the safety measures indicated, especially when handling the gas tank and during cutting and welding processes.

At the end of this manual, the user will obtain a functional and durable grill suitable for outdoor use, demonstrating the reuse of materials through manual fabrication processes.

Materials

1. 1” x 1” square steel tubing (PTR)
2. 1/4” steel flat bar
3. Empty and depressurized gas tank
4. Metal hinges
5. 6013 welding electrodes
6. High-temperature paint

Welding equipment

1. Welding machine
2. Chipping hammer
3. Wire brush

Tools

1. Angle grinder
2. Metal cutting disc
3. Grinding disc
4. Flap disc (finishing)
5. Drill
6. Metal drill bits
7. Square (essential for PTR)
8. Measuring tape
9. Permanent marker

Safety equipment

1. Welding helmet
2. Leather welding gloves
3. Safety glasses
4. Hearing protection
5. Welding apron
6. Cotton clothing

Approximate Measurements

First, we will cut the gas tank in half. To do this, we will use an angle grinder with a cutting disc, always following the appropriate safety measures.

It is very important to make sure that the tank is completely empty and depressurized before making any cuts.

To start the structure, we will make the legs. For this, we will use 1” square steel tubing (PTR). The legs will be made with the shown shape, which does not have fixed measurements, as they depend on the user’s needs.

However, it is recommended to keep the same proportions to ensure stability and good appearance. Use one half of the tank as a reference to guide the shape of the legs and achieve a better fit.

Two pieces with this shape will be made and then joined using a square steel tube (PTR) of the same size. The final result will be very similar to the reference images provided as a guide.

In this step, the half of the tank will be welded to the leg structure already assembled. Then, a steel rod will be installed as a stop for the grill; this part can also be made using flat bar.

The important thing is that it works as a stop and support for the grill that will be made later.

The next step is to install the hinges, aligning the lid with the base. It is very important to make sure both parts are properly aligned so the hinges are positioned correctly.

The hinges will be welded so that one half is attached to the lower part and the other half to the upper piece.

The next step is to make the grill. For this, a section of flat bar will be shaped so it fits inside the grill and works as a frame. This can be done by hand; however, using a bench vise is recommended, as it makes the shaping process easier and gives better results.

In the same way, the grill bars will be made using flat bar. There is no exact measurement for this step; however, it is recommended to leave approximately 1 cm of space between each bar.

The next step is to make the handles for transportation and the front handle to open the grill. For this, we will use the flat bar we already have.

To make the process easier, it is recommended to use a bench vise; if you do not have one, it is not a problem, it will just be a bit more difficult to bend the material.

In my case, the tank already had two handles, so I only needed to make one additional handle. If your grill does not have handles, you will need to follow the same process using the flat bar we have.

To finish, make sure all welded areas are smooth. For this, use a grinding disc on the angle grinder.

After this, we will install the chimney on the grill.

Although I used a round tube for the chimney, you can also use 1” square steel tubing (PTR). To make the opening, an angle grinder with a cutting disc was used, marking a square that allows the smoke to exit and is not visible once the chimney is installed.

After this, the only step left is to apply spray paint. It is important to make sure the paint is suitable for high temperatures. It is recommended to apply 2 to 3 coats for the best result.

The inside of the grill should not be painted.