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I rescued a little wonder of a Kamado-style cast iron BBQ from years of neglect and obscurity out in my father's yard. I have a lot of great memories , meals and camping trips tied to this BBQ; The unit is almost as old as I am, and it and my father became my inspiration for smoking meats today (something I just recently realized).
Here's what she looked like when I first picked her up. The wood handles and base were completely gone, as were the lower vent drawer and the grate-lifting tool designed for servicing the coals.
The coal and cooking greats were barely intact -- just enough to use as a template for new grates. The originals are cast iron; the new grates will be steel.
The original colors scheme was dark burgundy on the top and black on the bottom. I disassembled the BBQ and saved all of the old, rusted hardware to guide my selections for replacement parts. I chose brass hardware & fittings which provide nice accents to the restoration. I could not find any type of high-temp burgundy paint, so I opted for Ford engine red (rated up to 550*) purchased at the local auto parts store. After wire brushing and grinding off years of dirt and rust, I applied the paint.
I turned new handles out of oak on my lathe. The base is also cut from the same oak plank. I also welded a new lower vent and turned an oak knob (an upgrade from the original vent which had a snap ring as a handle). I thought painting the vent red gave some great contrast.
On to the grates. I finally had some time to run across the valley and pick up 20 feet 1/4" X 1/2" steel for $8.00. First, I carefully bent and welded the outer ring, using the original grates as templates and test fitting the rings in the BBQ. They sat perfectly on the little mounts in the casting. I fired up the buzz box stick burner and went to town, ending up with some pretty decent looking grates for someone who doesn't weld very often. The welds aren't pretty, but they hold. Everything survived a couple of good drop tests on the driveway. Here's the new cooking grate next to the original:
The newer heavy duty steel should last quite a bit longer than the old cast iron grates.
I made a new grate lifting tool so I can service the coals/wood and turned a matching handle.
I sprayed the inside with Olive Oil and loaded some coals in to season her. My dad says she runs on just a handful of coals for hours (about 6 or 8 -- if his memory is accurate. It was
). I used Rancher hardwood coal for my cooks (provides some nice smoky flavor) along with hickory wood chips for added smoke. This is a pic of the first smoke she has seen in 25-30 years!
Here's the first meal on the re-inauguration smoke! A small pork roast and a couple of sausages that needed Q-ing.
The money shot...
And the shot that says it all!!!!
Dad had the first serving, and it was every bit as good as we both remember! Thanks for looking!
Here's what she looked like when I first picked her up. The wood handles and base were completely gone, as were the lower vent drawer and the grate-lifting tool designed for servicing the coals.
The coal and cooking greats were barely intact -- just enough to use as a template for new grates. The originals are cast iron; the new grates will be steel.
The original colors scheme was dark burgundy on the top and black on the bottom. I disassembled the BBQ and saved all of the old, rusted hardware to guide my selections for replacement parts. I chose brass hardware & fittings which provide nice accents to the restoration. I could not find any type of high-temp burgundy paint, so I opted for Ford engine red (rated up to 550*) purchased at the local auto parts store. After wire brushing and grinding off years of dirt and rust, I applied the paint.
I turned new handles out of oak on my lathe. The base is also cut from the same oak plank. I also welded a new lower vent and turned an oak knob (an upgrade from the original vent which had a snap ring as a handle). I thought painting the vent red gave some great contrast.
On to the grates. I finally had some time to run across the valley and pick up 20 feet 1/4" X 1/2" steel for $8.00. First, I carefully bent and welded the outer ring, using the original grates as templates and test fitting the rings in the BBQ. They sat perfectly on the little mounts in the casting. I fired up the buzz box stick burner and went to town, ending up with some pretty decent looking grates for someone who doesn't weld very often. The welds aren't pretty, but they hold. Everything survived a couple of good drop tests on the driveway. Here's the new cooking grate next to the original:
The newer heavy duty steel should last quite a bit longer than the old cast iron grates.
I made a new grate lifting tool so I can service the coals/wood and turned a matching handle.
I sprayed the inside with Olive Oil and loaded some coals in to season her. My dad says she runs on just a handful of coals for hours (about 6 or 8 -- if his memory is accurate. It was
). I used Rancher hardwood coal for my cooks (provides some nice smoky flavor) along with hickory wood chips for added smoke. This is a pic of the first smoke she has seen in 25-30 years!Here's the first meal on the re-inauguration smoke! A small pork roast and a couple of sausages that needed Q-ing.
The money shot...
And the shot that says it all!!!!
Dad had the first serving, and it was every bit as good as we both remember! Thanks for looking!
for saving and preserving a family heirloom and rekindling the memories that go with it. Man you did it right too. 
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