Beef-in-a-barrel Barbecue

“That’s how cattle people cook in for a crowd. You can rig your own barrel cooking up to 40 lbs”

These unconventional steel barrel BBQ’s are ideal for large scale barbequing. In each barrel you can cook up to 40 lbs of beef, roast, or 20 chicken halves at one time.  The barrel BBQ’s are relative inexpensive, simple to make, and easy to transport to parks or campgrounds because you can cook a lot of food at once, they are especially popular in groups in Northern California, the California Cattlewoman’s Association often cooks up to 600 lbs. of beef at a time using 15 barrels. The Jones County Volunteer Fire Dept. has made a specialty of barbequing chicken cooked in a barrel.

What you'll need
50-55 Gallon Drum
2-Six Inch metal gate handles with bolts and nuts
2-1/2 by 34 inch lengths of steel rod (steel reinforced bars work well)
2-1 1/2 by 8 Inch metal straps
4-1/8 by 1 1/2 Inch stove bolts with nuts
24-1/8 inch washer
2-round end cuts from a 1 pound food can
21 to 22 Inch diameter barbeque grill  (or cut non galvanized steel screen cut just smaller than the inside dimension of the barrel)
2-Bricks
Container such as a non galvanized oil pan of base of an inexpensive round portable barbeque

Tools
Hammer
3/4 Cold Chisel
Metal File
Electric Drill with 1/2 and 3/4 high speed drill bits
Heavy Duty metal Sheers or saber saw
 

Where to Start
Where to get a barrel: Used steel barrels also called drums aren’t hard to find.  Check the yellow pages under barrels and drums or steel distributors and warehouses.  Ask for a 52-55 gallon steel drum with removable lid.  Check to see that the lid fits tightly (to eliminate heat loss during cooking) and, if possible, select one with a 2 inches threaded pouring hole in the lid.  Be sure the lid is either clean or reconditioned.  Never use a barrel that has contained pesticides or other poisonous substances (it should have a skull and cross bones or equivalent warning).  Expect to pay $25-$30.  You’ll find the other items readily available at a home improvement center.

Making the BBQ, with help or do it yourself:  The easy way out is to take your barrel to a welding shop and have them cut out the bottom, make the side and lid vent holes, and weld the handles to the lid.  We found welding charge from $20-$45 for this work.  You’ll still have to make the vent covers and mount the grill yourself.  If you have the time, muscle, and a few tools you can do the complete job yourself. 

Set barrel lid aside.  Build a big enough wood fire inside the barrel to blaze out of the top.  Let it burn until the inside surface if burn free of all substances.  When cool, empty ashes, hose clean, and let dry.  Using the hammer and cold chisel, cut out bottom just inside the rim.  This process requires some determined, noisy banging.  Hold the chisel at about a 30º angle as you cut sideways around the rim like a can opener.  With bottom cut out use the hammer to bang any sharp edges flat against the sides. 

Bolt the handles to opposite sides of the lid through predrilled holes.  If your barrel lid does not have a hole draw a 2 inch circle on lid about 2 inches in from rim.  Just inside the circle drill a ring of small pilot holes, then punch out the circle with a hammer and chisel, or use a saber saw or metal shears.  File sharp edges smooth.  Use the same method to make a second air vent in the side of the barrel about 4 inches above the bottom (see diagram). 

Make covers for the vent using the round can ends (or scraps of steel). Bend the metal straps as shown in the drawing and pre drill holes through them and barrel; using stove bolts through the holes attach straps to each vent cover and to the drum side and lid.  Use washers to help ensure a tight fit. Vent covers should pivot easily.  To install the support bars, drill or punch two (2) pairs ¾ inch holes on opposite sides of the barrel about 12 inches apart and 9 inches down from the top rim.  Run the metal holes through the rods set grill on support bars. 

To hold the charcoal you can use an non galvanized oil drain pan (available at auto part stores for less than $10), the base from an inexpensive round portable barbeque, or even an old plow disc.  Punch holes for ventilation in a pan or barbeque sides about 2 inches apart just above the base.

 

Now What?

Step 1 - Fifteen pounds of Charcoal briquettes burn in a metal pan steadied on two bricks.  Set the open en of the barrel over the fire.

Step 2 - Place whole rolled and tired cross-rib roasts (12 to 14 pounds each) slightly apart on the grill.  Rub meat first with paprika, salt, pepper, and lemon pepper.

Step 3 - Set lid in place; keep dampers on lid and slide 3/4 open.  turn roasts after 2 hours; insert meat thermometers in center of roasts

Step 4 - After about 4 to 5 hours, roasts are richly browned and have an internal temperature of 135º to 140º - Medium Rare and succulent.