Make your backyard steel braai – step-by-step guide Step 1: Welding

You can now buy a 230 V wire-feed welder for a very modest price. All of the welding we did on this project was done with 0,9 mm flux-cored wire, although you can gas weld if the metal you choose is thinner. Alternatively, if you have an arc (stick) welder, 10 gauge is about as thin as you can weld successfully. Step 2: Cutting

I welded the ends on first, keeping distortion to a minimum, and then cut the holes for the doors.

Step 3: Cutting

A 5 cm holesaw gives nice rounded corners. I had to cut only three-quarters of the way around the openings because I used the unwelded seam for the bottom of the door. Step 4: Cutting

The steel can be cut with a sabre saw, but it's laborious and consumes a lot of blades. I also tried cutoff wheels on the grinder, which was somewhat faster, although it threw a lot more sparks. Next time, I'll beg, borrow or steal a plasma cutter.

Step 5: Bare metal

We had a local sheetmetal shop cut the pieces to size and then roll the drum sections for us. You can use just about anything made of steel – as long as it's not galvanised. If you can find one, try a food-grade steel barrel. Step 6: Trim

An inexpensive piano hinge keeps the doors tightly sealed. I used pop rivets, but sheetmetal screws would work.

Step 7: Trim

Wooden handles, which stay cool enough to touch, are held in place by bolts and brass spacers. The handle was sanded and paste waxed. Step 8: Smoke management

The chimney is 75 mm chimney pipe.

Step 9: Smoke management

The low-tech firebox damper is the end of a soup can. Step 10: Smoke management

The connection between the firebox and smoke chamber is a 50 mm water pipe, with the collars from a pipe union for nuts. The firebox hangs from this connection, which is surprisingly airtight. A bolt and wingnut lower down keep everything solid. With everything assembled and painted, it's time to build a hot fire in the firebox, and get all the metal hot enough to set the paint and burn off any mill scale and cutting oil lingering inside. After it all cools off, wash everything and paint the inside of the smoke chamber with vegetable oil to prevent rusting.

Step 11: Build your own backyard braai

[1] Lump-style charcoal [2] Firebox damper door [3] Firebox with tight-fitting door [4] Smoke chamber with chimney [5] Stainless steel grill [6] Seasoned oak and apple wood [7] Dinner — in about 4 hours