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

Building your own brick barbecue with a chimney is a fun and rewarding DIY project. The smell and taste of food cooked over an open brick fire is unbeatable. Constructing the BBQ yourself allows you to customize the dimensions and design. While it requires time and effort, you’ll save money compared to buying a pre-made brick grill. Follow this step-by-step guide to build your own chimney BBQ from scratch.

Planning Your Brick BBQ

Proper planning is crucial for a successful DIY brick BBQ build. Here are some key steps:

• Check local building codes – Some areas regulate the height and location of outdoor brick ovens and chimneys,

• Choose a location – Pick a flat spot in your yard away from trees and your house.

• Decide on dimensions – The interior size depends on your cooking needs. Standard size is 4 feet wide by 2 feet deep.

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

• Have utilities marked – Call 811 before digging to avoid hitting any buried electric, gas or water lines.

Constructing the BBQ Foundation

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

• Mark the area using stakes and masonry line.

• Excavate 8-12 inches down.

• Fill hole with 3 inches of compacted pea gravel for drainage

• Build wood forms if making a above-ground slab foundation.

• Mix and pour a 4 inch thick concrete slab and let cure completely.

Laying the First Course of Bricks

With the foundation set, it’s time to start stacking bricks:

• Use a brick hammer to cut any custom shaped bricks needed.

• Mix mortar according to package directions.

• Apply a 1⁄4 inch mortar bed on foundation.

• Press first bricks into mortar with 1⁄2 inch gaps between for expansion.

• Check corners for 90 degree angles and level frequently.

• Tool mortar joints with a jointer for concave finish.

• Let mortar cure overnight before continuing.

Adding Additional Brick Courses

• Apply mortar on top of lower courses using a trowel.

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

• Use half bricks as needed to create pattern.

• Tool joints after each course. Remove excess mortar with brush.

• Build up back and side walls to desired height in same manner.

• Leave front open for access.

Creating Grill Grate Ledge

The grate ledge supports the cooking grates inside the grill:

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

• Stagger placement of ledge bricks in each layer.

• Install ledge bricks on rear wall for multi-level grilling zones.

• Ensure ledge protrudes just enough to hold grates.

Constructing the Chimney

The chimney draws heat and smoke up and out of the barbecue:

• Use metal flue pipe or construct chimney from bricks.

• Make sure chimney opening aligns with BBQ interior.

• Surround chimney with metal flashing at joints.

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

• Caulk joints with high-heat silicone sealant.

Finishing Touches

• Install heavy duty steel grill grates designed for masonry BBQs.

• Apply multiple coats of heat resistant paint made for masonry.

• Seal any cracks or crevices with high-temp caulk to prevent smoke leaks.

• Consider adding decorative stone or brickwork details.

Using Your New Brick Barbecue

Once completed, keep these usage tips in mind:

• Let mortar cure for at least 28 days before first use.

• Start with a small fire to slowly cure and season the brick.

• Pre-heat grill for 45-60 minutes to get temperature stabilized.

• Use lump charcoal and hardwood chunks for best flavor.

• Keep chimney clear of debris to ensure good airflow.

• Cover BBQ when not in use to protect from weather.

• Clean interior regularly by scraping off grease and food debris.

With proper construction and care, your hand-built brick barbecue with chimney will provide years of delicious grilled food and memories. The sense of satisfaction you’ll gain from creating it yourself makes the effort worthwhile.

FAQs about Building a Brick BBQ

Here are answers to some common questions about constructing your own brick barbecue:

What kind of bricks should be used?

Use solid clay bricks rated for high heat, not decorative bricks. Firebricks are ideal.

What temperature can a brick BBQ reach?

Properly built brick barbecues can reach 600-700°F. Higher with additional airflow from chimney.

How thick should the concrete foundation be?

4-6 inches thick is ideal. Make above ground foundation at least 6 inches thick.

Should the chimney have a rain cap?

Yes, a rain cap prevents water from entering and helps draw smoke up.

How much mortar is needed?

Figure about 1 bag of mortar per 100-150 bricks for entire project.

Can it be built on a patio or wood deck?

No, the extreme heat requires a non-flammable concrete or stone foundation.

What maintenance is required?

Repoint any cracked mortar annually. Clean out ashes and grease buildup regularly.

How long will it last?

A properly constructed brick barbecue with chimney will easily last 20-30 years or more.

Building your own custom brick barbecue grill with a chimney is a big project but hugely rewarding. The effort is well worth it when you get to cook on a BBQ you made entirely yourself. With this step-by-step guide, you’ll have the knowledge needed to DIY your own brick grill. Fire it up and enjoy!