How to Make a Barbecue Grill From a Whiskey Barrel

Whiskey barrels are plentiful and make interesting and effective barbecue grills.

The inside of a whiskey barrel is made of wood that has adopted the aroma and flavor of the whiskey it once contained. The whiskey-saturated wood provides a fragrant aroma while enhancing the flavor of the food. The thick, tightly placed wood staves retain heat and direct it to the top of the barrel to grill the food. The whiskey barrel is a good conversation starter that requires little technical knowledge and time, and few materials, to build.

Things You'll Need

• Liquid dishwashing detergent
• Electric drill motor
• 3/8-inch diameter drill bit
• 3/8-by-1-inch galvanized wood screws
• Heavy duty plumber’s strap
• Jigsaw
• Tape measure
• Door hinge
• Hook and eyelet latch
• One-burner electric stove
• String
• Carpenter’s level
• 3/8 diameter, 8-inch bolts, with matching nuts and screws
• 3 wire grill racks
• Aluminum pan
• Door handle

Instructions

1. Wash the barrel thoroughly inside and out with a solution of liquid dishwashing detergent and hot water. Allow the barrel to dry completely.

2. Drill a 3/8-inch hole through each metal ring into the middle of the barrel stave behind it to a depth of ¼ inch. Repeat the same process on the remaining metal rings and staves. Thread a galvanized screw tightly into each hole to firmly attach the staves to the metal rings.

3. Lay a strip of heavy-duty plumber’s strap around the top of the barrel 4 inches above the top metal ring. Drive screws through the plumber’s strap into the middle of each wood stave to hold the staves together. Use a jigsaw to cut around the top of the second ring to remove the top of the barrel.

4. Cut an 18-by-10-inch hole in the barrel; center it between the bottom ring and the ring above it to create a door to insert and remove the heating element as needed.

5. Position a strip of heavy-duty plumber’s strap at the top and bottom of the inside of the door you just cut out. Screw the strips of plumber’s strap to the inside of the door to keep the wood door staves together.

6. Screw two hinges to the left side of the door to attach it to the barrel, according to the manufacturer’s directions. Attach a simple hook-and-eye latch to the right side of the door and barrel.

7. Place the heating element on the inside bottom of the barrel and measure 1 inch above the top of the heating element. Make a mark on the outside of the barrel in the middle of one of the wood staves. Remove the heating element from the barrel.

8. Place the end of a string on the mark you just made, pull the string around the barrel and tie it to the other end of the string. Use a carpenter’s level and a tape measure to mark three spots that are equidistant from each other and level.

9. Measure 5 inches up from each of the marks you just made and mark these spots. Hold the drill horizontal and drill a 3/8-inch-diameter hole where you made each mark. Drill another set of holes 2 inches down from the top of the barrel in line with the holes previously drilled.

10. Slide a washer on a bolt, push it through a hole and apply another washer on the other side; thread a nut on the bolt and tighten it securely. Repeat this procedure on each of the other holes until all nine holes have bolts secured in them.

11. Position a wire grill rack on top of the three bolts at the bottom of the barrel. Place a one-burner electric stove onto the rack and run the cord to a power source. Put a grill rack on top of the middle set of bolts and place an aluminum pan on top to catch drippings. Place the final grill rack on top of the top circle of bolts; this is where you will lay the meat for cooking.

12. Screw a standard screen door handle on top of the barrel lid so you can place it on top of the barrel to capture heat and remove it when the meat is done.

Tips & Warnings

• Monitor the heat setting on the electric stove and adjust as needed while cooking the meat.

• Never leave a barbecue grill unattended while in use.

• Find round or square grill racks that fit securely on top of the bolts sticking through the inside of the barrel, without falling through.

• Measure the temperature of the meat with a stem thermometer to make certain it is done.

References

• BBQ Forum: How to Make a Homemade Whisky Barrel Smoker – 7 Steps and You Will Enjoy Your Own Smoker