Alex, alias altanet, is an engineer from the Northwest with expertise in building and remodeling.
Year after year, I've considered purchasing expensive BBQ islands from showrooms. They are beautiful and shiny but poorly built, featuring plastic tops and spray-painted side panels that create the illusion of a stucco finish. Most of these BBQs fell apart after minimal use in my friends' backyards after only one year.
I really wanted a summer kitchen after considering the amount of time I spend cooking outside using my grill and smoker. I had already finished building a deck in my backyard, but I decided to add one more level for the installation of an outdoor kitchen and BBQ island. Below are the steps you need to build your own.
How to Build an Outdoor Kitchen and BBQ Island
Step 1: Estimate the size and shape
Estimate how big you want the island to be, and come up with an idea of the shape. Also, determine which BBQ you want to buy. I decided on a Vermont BBQ after reading about it on Amazon and checking the quality of the equipment at my local Home Depot. Try to get a BBQ with straight corners, a side burner, and wheels. For me, it made sense to buy the complete unit, instead of purchasing the head and side burner separately.
The Vermont BBQ with a side burner cost $649. I bought a couple of 20% off coupons on eBay and got the BBQ for $519. You should get your construction materials at the same time so that the coupon works for 20% off the total purchase.
Step 2: Decide on the style and number of doors
Decide which stainless steel doors you want and how many. Measure them on a Weber grill at the store. Call Weber and order the ones you decide on. They should cost about $40 each. So-called "Door Kit for Built-in BBQ" sets cost about $400 from the same manufacturer. Avoid these.
Complete the framing with 2x4 PT boards, calculating how long and high you want the walls to be. Good measurements will save you some cutting when you install the 12x12 stone slate tiles (they are actually 11 3/4"x11 3/4").
Considering the 1/4" spacing that is left over, you should make the top 24" wide, enough for two slates. When framing openings and doors, remember to make openings 1/2" larger than you need, taking into consideration the thickness of the beckerboard, adhesive, and slate layered on top of each other.
So for a 20x20 door, you will need to frame the opening at 20 1/2"x20 1/2." Also, remember to angle the top slightly backward to allow rainwater to run off into the yard.
Step 3: Run the conduits
Run conduit for the outlets, lights, and water pipes during the framing process.
Step 4: Install 1/2" beckerboards
Install 1/2" beckerboards. Do not use Wonderboards, as these are for floors and are not as tough as Hardibeckers. You will need a special blade marked for cutting Hardiplank siding to cut these.
Step 5: Install stone slates
Install natural stone slates. These cost 90 cents each with a coupon. I chose a beautiful color that can withstand harsh weather. I also bought a simple 12" chop saw on eBay to cut the tiles. It cost $30 and came with a diamond blade.
Step 6: Seal the slated surfaces
Use a polymer synthetic blend as a mortar and, for grout, use Keracolor S Sanded to fill in the extra spaces. Upon washing off excess grout and letting the stone tiles dry, I applied Impregnator 511 sealer to all of the slated surfaces.
Step 7: Extra additions
Because the Vermont grill was a stand-alone model and did not have a rear heat-resisting panel, I installed one sheet of galvanized steel behind the BBQ prior to rolling it in place. I also decide to add a refrigerator in anticipation of the summer months.
The total cost of the project was around $1200. This accounts for the cost of the grill, refrigerator, and materials. The materials alone cost less than $500.
This article is accurate and true to the best of the author’s knowledge. Content is for informational or entertainment purposes only and does not substitute for personal counsel or professional advice in business, financial, legal, or technical matters.
Questions & Answers
Question: If you, the writer of this article, had to do it again would you choose the tile or veneer?
Answer: Built new kitchen using metal studs, 1/2" backer board and veneer.
Question: What fridge did you, the creator of this article, purchase?
Answer: It was purchased at Lowe's, made by Char Broil
Ty on August 26, 2020:
I like this and am going to attempt to do something similar this weekend, Yev, why the metal studs? have you not BBQ on a wooden deck before?
E.H. on August 06, 2020:
What kind of wood did you use?
Michael on June 29, 2017:
I want to drop a Weber kettle into the top of the island worried about the heat if there would be a fire
Yev on July 18, 2016:
I would never ever use a wooden frame in a bbq island. Why even risk fire, and what burns better then anything? Wood. You can buy metal studs at Home Depot, it's a bit more work to make a frame out of it, but at least it's fire proof. The rest of the steps are the same, you can still attach backer board to it. Also if you in the northern states extra precautions need to be taken to waterproof hardibacker.
Mara Leach on June 27, 2015:
Did you allow for space for the vents on the sides and back of grill? If not, have you had an issues? We are trying to do this with a Kitchenaid stand alone grill, but are concerned about covering the vents.
Kelsey Elise Farrell from Orange County, CA on May 06, 2015:
Nice hub, I'll have to pass this onto my family who are in the middle of redoing their backyard.
Rick on February 14, 2015:
Nice job looks great.
Betty on October 09, 2010:
Thanks for sharing Robert. Betty
altanet on April 14, 2010:
This is as step-by-step as I did it few years ago. Still looks good, but I don't have any plans, since everything was tied up to the size of the deck, tile pieces and BBQ' dimensions.
Robert Ramirez on April 14, 2010:
By any chance you happen to have a step by step guide? if you do can you publish them or you want some $$ so I can use it to build mine?
cagie on June 24, 2008:
Nice design idea. I think I might have used 2" thick concrete block in the grill area to ensure no flamables are in contact.