How to Build a Chile Roaster

Roasting chile peppers gives them a smokey flavor that pairs well with grilled meats, strong cheeses and seafood.
Roasting chile peppers gives them a smokey flavor that pairs well with grilled meats, strong cheeses and seafood. (Image: Hemera Technologies/ Images)

Roasting chile peppers is the act of charring the skin using high heat. Chile peppers can be roasted on a grill, stove top or any other piece of equipment that creates flames. Using a grill or a stove to roast chiles requires you to put the chile pepper directly on to the grill grate or stove top burner. If the grill grate or stove top burner is dirty, the chile pepper may pick up some funky flavors. To prevent the flavor of a chile from being altered, build a chile roaster. A chile roaster is a rotisserie style vessel that sits above a flame and rotates the chiles as they roast.

Things You'll Need

  • Grill
  • Motorized rotisserie kit
  • Perforated aluminum, 24 by 36 inches
  • 2 stove pipe caps, 8-inch
  • 4 aluminum bars, 36-inch
  • 22-gauge stainless steel sheet
  • ½-inch stainless steel bolts
  • Washers
  • Nuts
  • Drill with drill bits
  • 2 adjustable wrenches
  • Tin snips
  • Welding torch
  • Welding mask
  • Black marker

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Building the Roaster

Roll the perforated aluminum lengthwise into a cylinder. The cylinder should be 36 inches long. Weld the adjoining edges together. Wear a welder’s mask while welding. This is the rotisserie basket.

With tin snips, cut a circle out of 22-gauge stainless steel that measures 2 inches larger than the cylinder in diameter. Cut the stainless steel circle into an “X.” This will become the inner support for the rotisserie basket.

Bend 1/2 an inch of each arm of the “X” to form a 90-degree angle. Drill a hole into the middle of the “X.” Use a drill bit that is the same size as the rotisserie arm included with the rotisserie kit.

Insert the four 36-inch aluminum bars into the rotisserie basket and space them evenly apart. Insert the inner support into the rotisserie basket to check the alignment of the aluminum bars. The bent edges of the inner support should align with the aluminum bars. Mark the location of the aluminum bars with a marker. Remove the inner support.

Drill three holes into each aluminum bar, one on each end and one in the middle. Insert a ½-inch stainless steel bolt into the outer holes on each aluminum bar. Put a washer and a nut onto the end of each bolt. Tighten each bolt using two adjustable wrenches to secure the aluminum bars to the rotisserie basket.

Drill a hole into the middle of each bent edge of the inner support. Insert the inner support and align the holes with the middle hole of each aluminum bar. Secure the inner support with ½-inch stainless steel bolts, washers and nuts.

Insert the arm of the rotisserie through the hole in the middle of the inner support. Position the arm so the tip (the part that is furthest away from the rotisserie motor) is aligned with the edge of the rotisserie basket. The other end of the arm should extend out of the basket.

Drill a hole into the middle of one of the stove pipe caps. Use a drill bit the same size as the arm. Insert this stove pipe cap onto the side of the basket at which the arm extends out. Drill holes into the side of the stove pipe cap and secure it to the basket with ½-inch stainless steel bolts, washers and nuts. Attach the other stove pipe cap to the other side of the basket, but do not secure it with bolts. The stove pipe cap not secured with bolts is the removable cap.

Insert the arm into the motor of the rotisserie kit and secure it via the manufacturer’s instructions.

Mount the rotisserie over a grill via the manufacturer’s instructions.

Using the Roaster

Preheat the grill to 450 degrees Fahrenheit.

Remove the removable cap from the rotisserie basket. Use tongs or wear heat-resistant gloves; the metal will be hot.

Add the chile peppers to the basket and replace the removable cap.

Cook the chile peppers until the skin turns black. As the rotisserie turns, the peppers are rotated in the basket so the skin should be charred evenly on each pepper.

Remove the removable cap and remove the peppers.

Put the chile peppers in a large bowl. Cover the bowl with plastic wrap. The heat from the peppers creates steam that will stay trapped in the bowl thanks to the plastic wrap. The steam releases the skin from the pepper and makes it easy to remove.

Steam the chile peppers for 10 minutes. Remove the plastic wrap.

Rub the peppers gently with your thumbs under cold running water to remove the skin.


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