How to Build a Brick BBQ With a Chimney – A Complete Step-by-Step Guide

Building your own brick BBQ with a chimney is a fun and rewarding DIY project for any backyard chef. The great tasting smoky flavor from cooking over an open brick fire is hard to beat. Constructing it yourself allows you to customize the size and design to perfectly suit your needs and tastes. While it requires some time and effort to build, you can save a considerable amount of money compared to buying a prefabricated brick grill and have the satisfaction of creating it yourself. This complete step-by-step guide will teach you everything you need to know to build your own chimney brick BBQ from start to finish.

Planning Your Custom Brick BBQ

Proper planning is crucial to ensure your DIY brick barbecue project goes smoothly. Here are some of the key planning steps to take:

• Check your local building codes – Many areas have regulations on the allowed height and placement of outdoor brick ovens and chimneys. Make sure to follow any requirements.

• Choose a good location – Pick a flat spot in your yard at least 10 feet away from trees and your house or wooden structures.

• Decide on dimensions – The interior size depends on your typical cooking needs. A standard 4 feet wide by 2 feet deep cooking area works well.

• Buy your materials – You’ll need concrete, bricks, mortar mix, metal grill grates, flashing, chimney cap, pea gravel and masonry tools.

• Mark any buried utilities – Call 811 before digging to avoid hitting any underground electric, gas or water lines while excavating.

Constructing the Solid Foundation

The foundation supports the considerable weight of the bricks and withstands the high heat Here’s how to build it

• Mark out the BBQ footprint using stakes and mason’s line.

• Excavate down 8-12 inches depth.

• Fill in the hole with 3 inches of compacted pea gravel to provide good drainage.

• Build temporary wood forms if making an above ground concrete slab foundation.

• Mix and pour a 4-6 inch thick reinforced concrete slab. Let it fully cure before continuing.

Laying the First Course of Bricks

Once your foundation has properly set, it’s time to start stacking bricks:

• Use a brick hammer to customize any special shaped bricks as needed.

• Mix up mortar according to the package directions to get the right consistency.

• Apply a 1⁄4 inch thick mortar bed on top of the foundation.

• Set the first layer of bricks into the mortar with 1⁄2 inch gaps between for expansion.

• Check corners frequently for 90 degree angles and use a level often to keep things plumb.

• Tool the mortar joints with a jointing tool to create an attractive concave finish.

• Let the initial mortar cure rock solid overnight before continuing.

Adding Additional Brick Courses

• Apply fresh mortar on top of lower courses using a trowel to adhere bricks.

• Lay bricks in a running bond pattern, staggering the vertical joints in each row.

• Use cut half bricks as needed to maintain the staggered running bond pattern.

• Tool the joints neatly after each course. Brush off any excess mortar promptly.

• Build up the back and side walls to the desired height in the same manner, leaving the grill front open for access.

Creating the Grill Grate Ledge

The grate ledge supports the cooking grates inside the barbecue:

• Turn two bricks up on their sides in each course to create the ledge.

• Stagger the placement of the ledge bricks from row to row for durability.

• Install ledge bricks along the rear wall as well for multi-level grilling zones.

• Ensure the ledge protrudes inward just enough to securely hold the grill grates.

Building the Chimney

The chimney draws heat and smoke upward and out of the BBQ:

• Use galvanized steel flue pipe or construct the chimney with additional bricks.

• Ensure the chimney opening aligns with the interior of the barbecue.

• Surround chimney joints with aluminum flashing for waterproofing.

• Install a concrete chimney cap at least 2 inches wider than the flue.

• Caulk all chimney joints thoroughly with high-temperature silicone sealant.

Applying the Finishing Touches

• Add heavy duty steel grill grates made specifically for masonry structures.

• Apply several coats of heat resistant, non-combustible masonry paint.

• Seal any remaining cracks and crevices with high-temp caulk to prevent smoke leakage.

• Consider adding decorative stonework or extra brick detailing if desired.

Using Your New Brick Barbecue

Here are some handy usage tips once your chimney BBQ is completed:

• Allow the mortar to cure for at least 28 days before lighting the first fire.

• Start with a small controlled fire to slowly cure and season the new brickwork.

• Always pre-heat the grill for 45-60 minutes to get the temperature fully stabilized before cooking.

• Use lump charcoal along with hardwood chunks for the best possible flavor.

• Keep the chimney clear of ash buildup and debris to maintain good airflow.

• Cover the barbecue when not in use to protect it from weathering.

• Frequently remove grease drippings and food debris by scraping the interior.

Maintaining Your Brick BBQ

With proper construction and care, your hand-built brick barbecue with chimney will provide decades of delicious smoky grilled food. Here are some tips for keeping it in top shape:

• Inspect mortar joints annually and repoint any cracked areas to prevent further damage.

• Check for cracks in the concrete base and repair as needed to prevent settling.

• Seal any new cracks in the brickwork right away with high-temp caulk.

• Repaint periodically to enhance water resistance and curb rust formation.

• Replace damaged grill grates when they become excessively worn or rusted.

• Keep the chimney and vent unobstructed and have it professionally cleaned if needed.

The sense of satisfaction and pride you’ll gain from building your own custom chimney barbecue entirely from scratch makes the considerable time and effort truly rewarding. With this detailed step-by-step guide, you now have all the essential knowledge needed to successfully construct your own high-quality brick BBQ that will provide years of mouthwatering grilled meals and lasting memories. Get ready to fire it up!