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A Weld.com YouTube video featured by Hunker shows a DIYer turning two used beer kegs and scrap metal into a portable grill and smoker that attaches to a truck hitch. The builder estimated the project cost at about $152, but it required advanced welding, metalworking tools and practice to manage the grill’s heat.
A DIYer featured in a Weld.com YouTube video built a portable grill and smoker from two used beer kegs and scrap metal, with the project costing about $152 according to Hunker’s report. The grill is designed to slide onto a standard trailer hitch, offering a custom alternative to store-bought portable cookers for tailgating and camping—but the build calls for advanced welding and fabrication skills.
For the build, the creator sourced a half-barrel and a quarter-barrel keg from a local brewery, along with angle iron, flat bar and aluminum diamond plate from a metal drop shop. The creator already had grill grates and 16-gauge stainless steel. According to Hunker, the new purchases were a 90-degree stainless-steel elbow, a two-inch exhaust pipe and a coiled grill handle. The reported cost was about $152; the source does not provide an itemized budget.
The video shows the builder making a charcoal tray and a separate firebox grate, then fitting the kegs with a cooking chamber, exhaust pipe and smokestack. To help the grill attach to a vehicle, the creator welded a square tube for a standard trailer hitch. Hunker reports that the work involved both TIG and MIG welding, with TIG used on thin endcaps and MIG on structural parts and the airflow components.
The build also required a cut-off wheel, fiber disc, chop saw, welder and plasma cutter. Hunker describes the fabrication as beyond the skill level of many casual DIYers. The video includes workarounds for layout and fit, including using receipt paper to measure the keg’s circumference and ratchet straps and clamps to address warping and gaps. Those techniques illustrate the particular build; they do not make the project a beginner-level undertaking.
A Hitch-Mounted Option With Trade-Offs
The project’s appeal is its combination of reuse and portability: a used keg becomes a cooking chamber, and the finished unit can travel on a vehicle hitch rather than remain fixed in a backyard. Hunker presents it as an alternative to commercial portable outdoor stoves, including Blackstone griddles, whose owners need to manage rust and regular care. The report does not compare the keg grill’s performance or long-term costs with specific commercial models.
There are practical trade-offs. Hunker says the kegs’ thin-gauge stainless steel heats quickly, which can cause temperature spikes, but retains heat poorly. That may make cooking less predictable than on a heavier cooker. The report advises trying the grill before relying on it to cook for a group. The estimated price also depends on access to used kegs, scrap material and tools the builder already owned, so it should not be read as a guaranteed cost for other makers.
hitch mounted charcoal grill smoker for truck
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How the Keg Grill Was Fabricated
The project joins two keg sizes into a grill-and-smoker setup rather than simply cutting one container into a basic cooking surface. The builder removed an end cap, added supports and fitted cut-to-size grates before cutting the main door. Hunker says attaching the hinges before completing the door cut helped keep the parts aligned and preserve the keg’s structure during assembly.
The source notes two less equipment-intensive alternatives: cutting a single keg lengthwise with an angle grinder to make a horizontal grill, or keeping a keg upright and drilling holes in its base to create a drum smoker. These are suggestions in Hunker’s report, not builds independently tested there. Whichever design is chosen, the article says the finished grill should be burned hot with charcoal for about an hour before food is cooked, to burn off manufacturing oils, labels and beer residue.
“The project cost about $152.”
— Hunker, reporting on the Weld.com YouTube video
portable charcoal smoker grill for tailgating and camping
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Cost, Safety and Cooking Performance
The report does not provide the video’s publication date, a full materials-and-labor budget, or details on how the grill performs over repeated use. It also does not independently verify the builder’s cost estimate or assess the finished unit’s hitch load, roadworthiness or compliance with vehicle and local rules. Readers should not assume that a design shown in a video is ready for towing or safe operation without checking the relevant equipment and requirements.
Cooking performance may vary with the keg’s condition, the fire and the build. Hunker warns about rapid temperature changes and recommends practice runs, but gives no measured temperature ranges or test results. The article likewise does not establish that every used keg is suitable for conversion or cooking. Its recommendation to burn off residue is a preparation step, not a substitute for checking the container’s history and condition.
MIG TIG welding machine for stainless steel fabrication
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Test Before Taking It Camping
Hunker’s immediate advice is to burn the completed grill hot with charcoal for about one hour before cooking, then run practice sessions to learn how quickly it heats and how well it holds temperature. The source does not announce a product launch, commercial sale or follow-up testing; the next step described is in the hands of anyone attempting the project.
Anyone considering the full build should first assess whether they have the welding experience, tools and materials needed for the work. The featured project uses metal cutting and welding, and its hitch attachment is intended for vehicle transport. The report does not offer a road-safety certification or engineering review, so the design’s suitability for a particular vehicle and journey remains to be established.
plasma cutter and metal fabrication tools
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Key Questions
What did the DIYer build?
A portable grill and smoker made from a half-barrel and a quarter-barrel beer keg, with a square tube designed to slide onto a standard trailer hitch.
How much did the project cost?
Hunker reports an estimated cost of about $152. The source does not provide an itemized total, and the builder already owned some materials and tools.
Is this a beginner DIY project?
Hunker says the featured build requires advanced welding and engineering skills and specialized equipment, including a welder and plasma cutter. It also mentions simpler no-weld or drum-smoker alternatives.
What should users know about cooking on it?
Hunker says thin-gauge keg steel can heat quickly and retain heat poorly, making temperature control less predictable. It recommends burning the grill hot for about an hour before cooking and practicing before serving a group.
Has the grill been tested for towing or long-term use?
The report does not provide independent testing of roadworthiness, hitch loads or long-term cooking performance. Those details remain unclear.
Source: rss
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