KBQ Built in to Outdoor Kitchen

[CALNZ]

Hi Rick good suggestion. I will do that at some point but want to get a bit further before bothering Bill.

I’m confident the cook box itself is safe as it’s high up and surrounded by concrete. and the location is far enough away from the house for sparks or anything else. But there is a tiny risk of getting an ember burn on a few nearby built in wooden planters but I don’t think they’re much of a fire risk.

Im thinking of adding the SS mesh mod I saw in the sticky thread somewhere- just for piece mind.

I’ve seen many pics on this forum of people cooking much closer to their houses, wood piles etc than what I would be comfortable doing with this unit.

Would be easy to fold a bit of steel mesh so it literally just slides on and of the sides of the firebox. Just as a further fail safe.

Can’t imagine airflow would be all that compromised.

Anyone else done this ?

[CALNZ]

Awesome thanks Histrix, I see now that it does fold over the top like I was thinking, when I first saw it on my phone I couldn't see the top folds and wondered how it was staying on (on PC now and its super obvious). I assume it just slides on and off?

Do you always use it or just when it's windy?

Ever get any embers popping out the open ends?

If you made another would you do anything different (I thought you could close at least one end)?

[hogdog6]

Ive used Histrix mesh idea probably since he originally posted whenever there is any breeze. His idea works perfectly

[Histrix]

It can slide off or just lift off. That picture was V1.0 just to see if that mesh size was appropriate. It is. I had planned to make V2.0 and fold the ends to cover the gaps at the end. However, it worked so well as is that I just never bothered to make it prettier.
I use mine all the time. The main reason was because I have my KBQ mounted on a rolling stainless steel table. That puts the firebox opening high enough that I wanted to avoid any popping embers from hitting me in an eyeball.

[CALNZ]

Awesome thanks Histrix,
Currently researching mesh locally, and I will make one also. Seems like it would be a good addition for Bill to consider to make it a touch safer. Perhaps he doesn't want to encourage people to be more relaxed around it, but I think it would be a net gain to avoid embers flying around overall.

[JGrana]

The mesh method works well. One word of caution though. I once tried putting the mesh like a large U - on the bottom openings as well as sides.
Had a great coal bed - one of my best. But, after the cook and all had cooled down - the tray that keeps the wood/coals above the lower zone - was slightly warped from the increased heat. A few taps with a 2X4 and hammer straightened it out (luckily).

[CALNZ]

Hi JGrana that is fascinating- I am struggling to imagine what lower openings you were trying to cover, do you mean the ones on the coal grate?
Please excuse my ignorance!

got a large piece of mesh to play with, slightly thinner gauge than the Histrix mesh so hopefully its strong enough. Wow steel is expensive right now.

[CALNZ]

Does anyone have any idea how close the rear of a firebox could get to a concrete wall before the flames and smoke from the firebox would discolor the wall behind it? Lid would be mostly on.

[Spinaker]

Tough to tell, but Depending on wind and other factors......I would think a 6-8 inches would be enough.

[Dr. Pepper]

CALNZ First, greetings, and welcome. Personally, I would plan on the KBQ not being 'built in', but rather have a slot where you can roll it into place, but roll it out for use? A few thoughts, besides the excellent points about the convection exhaust ports being free of obstruction:
Even with a drain pan, you can get drips from the purposefully placed holes in the bottom 4 corners. Don't want a hidden grease deposit in your new cabinetry
When 'poking' the coal bed, be prepared for some embers.
For cleaning, it's great to be able to remove the front door, remove the side panels, and then scrape/hose/drain.

Now, off topic: Can we see a photo of your Grillworks? Which model did you get?

[Spinaker]

I would also say that you should have a spot for it that makes it possible for you to remove it easily. This would mostly be for cleaning purposes. I love this idea of building it in, but make it easy to remove and put back in.

I would also see about putting a small drain in the bottom of the space where the KBQ will be sitting. This will make it easy to clean the area where the KBQ will be sitting. I saw this on another, similar application and I will certainly put this in when I build mine outdoor space.

It will be nice to have the cooking box up off the ground too, so the food is more accessible and easy for you to move in and out.

Also think about how you would like to arrange the power for the KBQ. I would look into all-weather, high heat plug ins for the power output. Or at the very least, a heat-resistance plug to run to the KBQ.

I would also make sure you leave enough space on either side of the unit so you have room to set food, pans or anything else you might be using while cooking.

I look forward to seeing how this develops! Let us know how it goes!

[CALNZ]

Dr Pepper

This is great feedback, thank you. I agree that having a roll in roll out slot is smart (changing tastes, MCS etc) but I have to balance with WAF and aesthetics- tried to find another location for a slot but with our inner city location it’s impossible to do without compromising the courtyard design. So unless I want be tending KBQ in the driveway while friends and family are spending time in the new courtyard o/kitchen area, then next best option was a ledge for kBQ and being happy with a few trade offs. At least it can be swapped for a kamado in future or any bbq that size, and easily removed and put back for cleaning.

My plan is to be able to use disposable stainless steel drip pans placed under the legs for longer fatty brisket cooks etc along with the internal drip pan. But your so right, that is a risk with the fat. And probably staining our new tiles with fat (which bound to happen anyway over time no doubt - they will be treated/sealed).

Re the Grillworks - I can show you what it will look like but it hasn’t arrived yet so no photos of the unit! I got the architectural 48 plus rotisserie and a few minor mods like the bottom ember guard that’s on the Exo models (windy where we are).

Man I’m super excited about that puppy. Looking forward to the learning curve. This will be her home once finished.

[CALNZ]

Spinaker

Awesome feedback. Thank you.

These are the new drawings based on feedback from everyone here. This will allow for easy removal and putting back for cleaning. Have made the ledge bigger for more space around it and the height should be ok for adding wood, but I can also stand on the ledge and get up to firebox that way, as there will be plenty of space to tamp fire etc - especially with SNS kamado next to it not the primo drawn here, as it’s width is much less).

Negatives of this I can see:

- grease could get on the wood slats on the front of the footing if they drop off and onto the tiles

- not sure we can add a drain as it actually sits on a concrete plinth that is the footing for the wall behind it so there’s no space underneath it even tho it looks like there would be.

- this means we will need a slight fall to ensure the water runs off it, and I’m wondering that might lead to temps hotter in back of the unit ?

- the unit is 14 inches off the ground (in metric cm’s in the drawings) so a little higher than is optimal for firebox but perfect for getting food in and out.

- hoping firebox won’t cause too much discoloration of concrete plastered wall behind it.

- agree with Dr Pepper that tamping embers - even with the mesh mod- could cause a burn mark or two on the wooden planter capping close by - will try and work on a solution to that.

- the KBQ can go left or right side in the cutout although the right side will mean door opens into more space (see small sketch of this top right on the drawing).

- there will be plenty bench space with an island behind the operator and to the left, but not on right hand side of it. Opening the kamado and using that as extra bench also doable when it’s not in use.

- smoke will blow around the kitchen when using it, hard to know how annoying this could be: fridge is directly across from it in the island so that’s one of those things. If unit is on the left the smoke will blow across top of the bench top. On the right side it will blow onto the kamado more so that’s probably better.

- will get power plugs inset into the side of the ledge in the cutout so easy to plug in

thanks everyone for your thoughts. Any further feedback on new setup be much appreciated.

cheers

[Histrix]

Your setup looks like it's going to be a great space.

One thing to keep in mind - the KBQ was designed so that when the door is opened it hangs a bit below level and the door handle rests on the ground which supports the door and keeps the hinge from potentially racking. Since your KBQ will be elevated the door will be left to hang by itself. That will probably not really hurt anything, at least as long as you avoid resting anything heavy on the opened door.

[CALNZ]

Yes it’s a great point. It would be pretty easy for someone to lean on it while reaching into the back, thinking it was more solid than it is.

It’s so well built, but that hinge wouldn’t take much weight I don’t think. I can’t think of any solution other than being careful and not leaving the door open for long periods. Presumably not a death blow if something does happen.

I don’t have the door removal kit I’ve seen mentioned here - is that still available these days ? Was it Bill from mem?

[Spinaker]

I have not heard from Bill in a while so I am not sure if he is still making the door coupler. However, I have use cotter pins in a pinch and they work just fine. Although the rod coupler would be much more ideal. Being able to take the door off is great for cleaning.

I would not worry to much about the drain, It is just an extra that would be nice to have. Using a stainless chaffing dish catches 99% of everything in the KBQ, so you should be fine for drippings being caught. I like to use these pans because they are built to last and they tend to stand up much better than disposable pans. The runners in the KBQ move little bit, so I find that the foil pans do not slide in as well..

As for the smoke, that might be something you may have to simply deal with. Unless you are will to put some ventilation in the roof over the kitchen, but I would think most of it will clear out with a slight breeze. (it will also make the whole area smell amazing)

As for the discoloration, I would consider looking at some black slate to put up behind the fire box, where a backsplash would be. I use that for a hot plate on one of my Kamado tables. It has stood up to the heat of anything I have put on it. And it looks really sharp when it is cleaned up and oiled. I love the look. Just a thought. When I do my build in, I am going to line the walls of my insert with something similar.

Keep us in the loop. I would love to see this whole project being put together and the finished product. Thanks for sharing this adventure with us. This is what makes this place really fun.

[CALNZ]

Thanks Spinaker. You are right about the smoke, it will just be one of those things. I intend to plug the KBQ into an outdoor rated plug with an on/off switch easily accessible. I'll definitely consider the splashback idea for potential discolouration- thats a great idea. Love to continue the updates, it's been an exciting project for me so far, and tons of changes from here already. You're right about the KBQ smoke smell, it is heavenly! Just don't overdose so you also taste it in the food!

[Histrix]

CALNZ - You can easily make the door removable. The kit that used to be sold was just a length of steel tubing with an inside diameter slightly larger than the outer diameter of the steel rod at the bottom of the door. You just need to cut the existing door rod at the mid-point (easily done with a dremel/rotary tool). Cut to length (6"/150mm would be fine) the tube and that slides over one of the door rod halves and Bob's your uncle.

Before I bought my KBQ I contacted Bill Karu to ask for some dimensions that weren't shown on his website. When I mentioned my plan to mount my KBQ on a rolling table he mentioned the caution about the door just hanging free and not resting on the ground. In light of that I changed the table I planned to use to a four foot (1220mm) long table that would be long enough to support the opened door.
Instead of going with the larger table I did give some thought to just making up a rod/leg that I could use to prop the door to keep it from bending lower if anything hefty was placed upon it. I did give some thought to making a pair of hinged legs mounted on each side of the door that would just rely on gravity to swing them into position when the door was opened. In any case the options can be simple or somewhat elaborate. Personally, I'd probably do nothing but just keep in mind the "Don't rest the heavy tray of ribs on the door" method.

[CALNZ]

Interesting. Great ideas re the door props. Yeh i'll try it on its own to start and see how sketchy it is, then look into exactly these ideas if necessary. Hopefully hindsight is a benign teacher if there is a learning.

I'll have to do the door removal mod. Ive got a great easy cleaning spot relatively close by, but the door is a bit of a pain. I can live with it, as I find it doesn't need cleaning that often as long as a drip tray is in place, but I can see it would make life easier.

[glitchy]

I used this tubing to make my door removable: https://www.amazon.com/gp/product/B0...e?ie=UTF8&th=1

[CALNZ]

Nice, thank you.

[Dr. Pepper]

This link should be pinned! Great.

[Redwng]

Welcome from St. Cloud, FL.

[Dr. Pepper]

CALNZ Here's a photo of what BBQBILL had sent me a few years ago. Like Spinaker had said, simply cut your existing rod near the middle, and you slip the ferule on one of the pieces, put the the remaining half of your original rod into the ferule, and slide the ferule over to center over your cut.



Here's some photos of hot lid management as well.

[CALNZ]

Dr. Pepper Great thanks, thats helpful, and good description of the door mod. I'm sold.

[RayBecue]

Hi CALNZ how did this project turn out? Inquiring minds want to know 😎