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Tommy Walsh's DIY Guide
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Tommy Walsh's DIY Guide (2001)(Empire).iso
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t4a.txt
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1998-10-08
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Summary
Building a barbecue involves many different skills and tasks.
Follow the steps below to find out more
1 Choosing the location
2 Choosing the materials
3 Preparing the foundations
4 Designing the structure
5 Cutting the bricks
6 Building a 'dry run'
7 Laying the first course
8 Laying subsequent courses
9 Fitting the tray brackets
10 Fitting the grill bracket.
11 Fitting coping stones
Tools
Shovel, mixing board, builderÆs trowel, bolster chisel,
goggles, gloves, spirit level, lump hammer.
Materials
Bricks or blocks, barbecue tray, brackets, mortar,
coping stones.
Step 1 - Choosing the location
The location for the brick barbecue needs to be chosen carefully.
It should not be too close to the house, a fence or hedge.
Do not construct it under a tree or near a childÆs play area.
There should be an escape route if it should catch fire.
Step 2 - Choosing the materials
Common house bricks will eventually crack from the heat.
An alternative material from which to construct your
barbecue is decorative walling blocks, ideally with
dual facing decorative patterns. The charcoal rests on
a removable tray and the food should be on an adjustable
grill. Galvanised wall brackets should be set into the
barbecueÆs structure at appropriate points for adjusting
the height of the cooking grill.
Step 3 - Preparing the foundations
The barbecue should be built on a solid surface such as a
patio or concrete. A patio should have a solid foundation,
a bed of sand will not be adequate. In this case it would
be worth laying a slab of concrete to take the weight.
It should be at least 100mm thick.
Step 4 - Designing the structure
Place the tray on the ground and lay out the bricks around
it. The perpendicular joints between the bricks must occur
at the halfway point of the brick above and below. This
is known as the bond. Design the Barbecue to take account
of this.
Step 5 - Cutting the bricks
At this point you may need to cut some of the bricks.
Remember to remove an extra 10mm for the mortar. First score
the brick all the way round on a bed of sand with a bolster
and lump hammer. Next use greater force to break the brick
along the score.
Step 6 - Building a 'dry run'
Before you actually build the barbecue lay out three or
four courses which should ensure your bond design works.
Do not use mortar as it is a 'dry run'.
Step 7 - Laying the first course
Lay the first course of bricks with a 10mm gap for the joints.
Check to ensure they are level. If the brick begins to absorb
water from the mortar then make the mortar a little wetter.
Step 8 - Laying subsequent courses
Whilst laying each subsequent course, check that joints are
in the centre of the brick below. Ensure that the wall is
vertical with the spirit level and it is not leaning over.
You should make sure that the tray still fits after laying
each course.
Step 9 - Fitting the tray brackets
On the ninth course fit the tray brackets into the mortar.
Set them at least 125mm from the back with at least 50mm
of bracket resting on a block.
Step 10 - Fitting the grill brackets
Use the same method to fit the brackets the grill will rest on.
To give some adjustment of the grill pan while in use, fit more
brackets between the three courses above the tray fittings.
Step 11 - Fitting coping stones
Use the same method as laying bricks to fit the coping stones;
the mortar should have a slightly lower proportion of sand to
cement (1:5 cement to sand rather than 1:6 for the mortar for
the bricks). Do not use the barbecue for at least one week to
allow the stones to set.