Built In BBQ: How Do You Build One?

Every avid grill master dreams of building his own permanent built in BBQ grill. Over the past two years I have been designing and building my outdoor built in BBQ. During this process I have compiled a mountain of information about designing and building your own backyard grill. The cost of the backyard built in BBQ really depends on three factors.

1. Size: How big of a grill do you need?
2. Structural Materials: What will the counter and cabinets be built out of?
3. The Insert: What type of insert will you use? Do you prefer a built in gas BBQ grill or a built in charcoal BBQ?

Size
There are three basic built in BBQ designs to accommodate many sizes of outdoor kitchen (let's be honest you aren't just looking to build a BBQ grill, you are looking for a full outdoor kitchen). These designs are easily expandable.

• The first design is a simple bar. These usually range from 4 to 8 feet and are ideal for a grill insert and a few feet of counter space. This design is also known as a built in BBQ island.
• The second design is an L design. This type of backyard grill has an extension running perpendicular to the bar. The L design allow for more counter and cupboard space; there is even room for a sink, if you want to go that far. 
• The third type of built in barbecue is a U design. It takes the L design and extends another bar off of one of the ends to form a U shape. This is the ultimate design that allows for maximum counter space and has room for an eating bar.

Structural Materials

The basic internal structure of the grill can be made of two materials, either wood or brick (cinder block is also acceptable). You should base your choice on the type of material you are most comfortable working with.The type of material matters when creating your built in BBQ plans. No mater what material you choose to frame in our grill, you will need to pour a good reinforced cement foundation at least 6" thick.

• Wood Frame: When building your outdoor kitchen with a wood frame the most important thing is to use pressure treated lumber. This will ensure that the frame doesn't rot over time. When framing the grill make sure to use standard framing procedures and space the studs 16" apart; If your frame will be holding a large amount of weight, like an Italian pizza oven or Brazilian churrrasceira it is a good idea to run the studs 8" apart to support the extra weight. After the barbecue is framed in cover the entire piece with cement board. This will give you a flat, smooth surface to work with when adding the counter tops and outer walls.
• Brick Frame: When using brick or cinder block to frame in your grill, make sure to run re-bar supports every 16" or so to ensure that the walls will stay straight over time. Always remember to run interior walls to support the counter and any grill inserts that will be on top. After the brick is framed in, use cement board to level top before putting in an insert or counter top. 

Once the basic frame is completed you will need to decide what type of finish you want to put on the walls and what type of counter to install. There are many options to choose from. Some popular wall finishes are red brick, rock veneer, and stucco. Stucco is the most cost effective option. Brick and veneer look good, but take time to install. For the counter top you have basically the same options as your indoor kitchen. When I built my grill I chose a slate tile, that has worked out great.  

The Insert may be the most important decision that you will have to make. This is the functioning piece of your grill and will probably be the most expensive. Gas built in BBQ inserts range from $800 to $10,000. Large stainless steel grills are the most expensive. Some even come with the bar that just needs to be placed on a firm foundation. This summer I am planning to build my Weber charcoal kettle grill right into the counter top. This will be a very cheap insert, and I love my Weber. 

Total Bare Bones Cost for Built In BBQ Grills: $2,540

1. Reinforced Cement Foundation (8 ft X 3 ft): $150
2. Wood Frame: $120
3. Cement Board: $60
4. Red Brick & Mortar (for wall veneer): $600
5. Slate Tile Counter Top With Treated Oak Trim: $110
6. Small Stainless Steel Grill Insert: $1,500

Please note that this is the lowest cost that I could come up with for a bare bones backyard built in BBQ. It doesn't include the patio or other amenities such as a sink, fridge, or cupboards.