If you didn't have access to heavy machinery or a factory that produced gas barbecue parts, it would be almost impossible to build one by yourself. However, you can make one as a home project by using a combination of new and old spare parts. And, because you can use old parts for this project, you can save more money than if you bought a new gas grill.
Step 1— Looking for Usable Parts
You will need to look for parts that are still usable in old gas grills. Search Craigslist and other online discount sites, garage sales, or thrift stores to find these used grills and their parts.
Step 2— Removing Serviceable Parts
Next, take out the parts that are still serviceable from the old gas grill. Avoid prying and pulling too much on them, as they are easily damageable. You can reuse and clean grill grates by dipping them in warm, soapy water, as long as they are not already thin.
Disconnect the propane tank and place it somewhere safe and non-combustible. You may have to clean other dirty parts with a clean wire brush and some water, depending on how old your spare grill is.
Step 3 — Taking Off the Hood
Once you are done removing and cleaning the old barbecue-grill parts, take off the hood by removing the springs that are located at the hinges on the grill top.
Step 4 — Taking out the Burner Assembly
Lay the remaining part of the grill on its back and remove the burner from the gas valves by taking out the valve pin with a pair of pliers. Once you have disconnected the burner, you can then remove the igniter of the grill by removing the side clips. Be careful doing this because the clips are made of breakable plastic.
Now, you can remove the burner. If there’s any grease leftover in the grill, clean it out by using a putty or drywall knife, or repair it using a coat hanger and some ammonia.
Step 5 — Making Your New Grill
Start making your new grill by painting the hood and installing it back into place. Place shelving slats inside the grill, and secure them using a screwdriver. Then, connect a new gas-collector box through the hole found at the top of the burner.
Step 6 — Connecting Gas Tubing
Install the new grate on the firebox floor and reattach the tubes that you removed earlier. Secure them with wire clips, and set the food grate in place.
Step 7 — Connecting the Igniter
To get your new gas grill ready to burn, install a new igniter by connecting its terminals with the red and black wires from the burner. Before using your grill, ensure that all parts have been assembled correctly and securely as to not cause a fire or endanger yourself. If you decide you'd prefer a barbecue that burns charcoal, you can always convert your gas-burning one.