Year 10 – BBQ Sequence

Hot Plate = 300mm x 300mm x 3mm (cut 1 plate steel)

1. Mark out, centre punch the 10mm hole for the centre. 

2. Drill using the 3.5, 7 and 10mm bits. 

3. Ensure you have a block of wood under the hot plate and clamp to the bench of the pedestal drill.

4. Set the mandrels on the Pan Brake to about 200mm and adjust the clamp to suit the thick hot plate.

5. Use the Pan Brake to slightly crease the centre of the hot plate along both diagonals.

Support Rails = 500mm x 12mm x 12mm (cut 2 SHS)

1. Mark out, centre punch and drill 4 holes 6.5mm, which are 40mm from each end. 

2. The holes must be drilled on the same face.

3. The support rails must be held securely in a machine vice.

Grill = 300mm x 12mm x 3mm (cut 10 flat bar)

1. Mark out and cut (using a hacksaw) all 10 grill bars. 

    DO NOT USE THE COLD CUT-OFF SAW the material is TOO small

2. File off any large burrs.

Side Rails = 805mm x 15mm x 3mm (cut 2 flat bar)

1. Mark out and cut (using a hacksaw) the 2 rails.

DO NOT USE THE COLD CUT-OFF SAW the material is TOO small

2. File off any large burrs.

3. Using a vice and a large forging hammer, bend each side rail at 90o (305mm from one end) 

Once all the parts are ready you are now ready to weld!

Weld - Support Rails to Hot Plate

1. Welding settings - voltage 4

                              - feed rate 4

                              - check earthing clip

                              - gas 15L/Min

2. Place the support rails on the underside of the hot plate. 

3. The leg holes should face outwards.

4. The rail should be flush with the end of the hot plate and the side edge.

5. Use small tack welds along the length of the hot plate.

Weld - Grills to Support Rails

1. Use the same welding settings

2. Place the grills on the top side of the support rails, with about 5 to 8mm spaces

3. The grills should be flush with the edges of the support rails.

4. Use very small tack welds on the ends of each grill

ONLY make the legs once the main BBQ parts are welded, so that teasing the legs into shape is easier.

Legs = 750mm x 6mm (cut 2 rod)

1. Mark out and cut (using a hacksaw) 2 rods. 

    DO NOT USE THE COLD CUT-OFF SAW the material is TOO small

2. File off any large burrs.

3. Using a vice and a large forging hammer, bend the tabs at each end of the legs (ensure that the tabs face towards each other)

4. Measure 200mm from the tabs and bend the legs so that only 300mm remains flat (again ensure that the tabs face towards each other) 

5. Tease the legs so that they fit into the support rail holes easily.

Stoppers = 30mm x 12mm x 3mm (cut 4 flat bar)

1. Mark out and cut (using a hacksaw) all 4 stoppers. 

    DO NOT USE THE COLD CUT-OFF SAW the material is TOO small

2. File one end of each stopper to a 12mm radius and remove all burrs.

3. Place the stoppers 20mm from the end of each support rail and weld in place

This should provide a 60o angle once the legs are fitted

• The legs can now be fitted and left in place

• It may be necessary to tease the legs a little in order for them to fit easily into the hole and to sit flat on the floor.

• Clean all surfaces with methylated spirits

• DO NOT PAINT or apply a surface finish as this will taint the food when used.