This stone grill uses a 16-inch-by-32-inch drop-in grill unit with a built-in charcoal tray that adjusts up and down to regulate the amount of heat at the cooking surface. The outdoor barbecue grill is a beautiful addition to your outdoor kitchen or the perfect spot for cooking during your backyard barbecue parties.
We built firebricks around the grill unit and used fire clay mortar or refractory cement to joint them in place. For layout and planning purposes, the nominal size of these bricks is 9 inches by 2½ inches by 4½ inches. If your fire bricks need to be cut, have a masonry supply store do it, or use the old hammer and chisel after scribing the cut line.
To construct the inner core you'll need common concrete building blocks, sized 12½ inches by 7½ inches by 5½ inches. The cap or top of the structure is entirely up to your discretion. The most common materials used are flagstone, red brick or simply a leveled surface of cement. No matter what material you select, be sure to seal it with a good coat of waterproofing masonry sealer.
To securely tie all these components together, first you will need quarter-inch rebar, placed in a grid pattern with a 6-inch to 9-inch spacing in the concrete portion of the foundation. Second, you'll need a layer of heavy-gauge wire mesh set between each concrete block layer and between the first layer of block and the foundation. Let the wire extend 6 inches to 9 inches out all the way around the block so that you can weave the wire between the fieldstones and mortar. In some instances it will be necessary to cut the wire to bend it to the shape needed, so have a good pair of wire cutters handy.
Step 1: The Foundation
- Dig a hole to a depth of 24 inches. Install posts and 2-by-6 boards (keep the boards level). Add layers of sand and large stones, then add the smaller stones and work in more sand. Note: after the large stones are in the pit, shovel in a layer of sand. To work the sand down into the crevices, hose it down with water. Use just enough water to work the sand into the voids. Keep adding sand until the rocks are just covered.
- Add a 2-inch layer of sand and tamp it down. Keep adding and tamping until it's flush with the bottom of the 2-by-6 forms.
- Mix and add post hole concrete. After you have filled the form with 3 inches of concrete mix, lay the quarter-inch rebar horizontally in the concrete before pouring the remaining mix.
- Screed (level) the top flat using a 2-by-4. Keep the surface wet for 48 hours, using watersoaked burlap bags.