How to Make an Insulated Grill Jacket

Do You Know About an Insulated Grill Jacket and Its Uses?

To maintain consistent cooking temperatures throughout, consider insulating a barbecue grill both inside and out. The body of the grill absorbs and emits a significant amount of the heat produced by the grill’s flame. By adding layers of insulation, heat is reflected back onto the food, enabling faster and more effective cooking. Properly insulating a barbecue grill will help maximize the efficiency of both the fuel and the food you’re preparing.

An insulated grill jacket is a tool that is not required by everyone. Many grills that are built using fireproof material do not require an insulated grill jacket, they are fine on their own. However sometimes for any reason, a grill is made close to any area that is near to flammable material. This can be anything from being on a fairly small property and being forced to build your grill close to your wooden patio, to a bit of a mistake in planning that forces you to seek some kind of contingency.

Step 1-Plan the Concept and Draw it out, as well as Take The Precise Measurements

Having the plans drawn out, with exact measurements and dimensions, aids greatly in staying on track throughout a project. Refer to it frequently and create plans for items like

  • cabinet door cutouts
  • Material thicknesses such as 2x4s (which are not 2inx4in), concrete board, brick or stucco work, and so on.
  • fuel pipelines
  • adequate heat barrier

For example, if you want a space to be 39in wide when finished, you must arrange your frame to include a layer of concrete board, thus if you use 5/8in the concrete board, you must enlarge the entire area by 1 1/4in (5/8 on each side). And you must plan for it in every dimension.

Step 2-Using Pressure-treated Timber, Construct the First Piece

Because the grill will be outside, choose pressure-treated timber. It not only withstands the environment better, but it is also somewhat more heat resistant than standard timber. But don’t rely too heavily on it because if you do not put up a sufficient barrier, it will undoubtedly catch fire.

Because they will not all be the same (as you can see, the front one has a cutout for the cabinet/door), it was easier to take them one at a time. We then linked them together.

Step 3 – Insulate Using Wire Mesh

We intended to add a layer of fire retardant insulation to the core of our heat barrier. To hold the insulation in place, install wire mesh between the supports throughout the whole grill area.

Step 4 – Metal Framing Surrounding the Grill Area 2x4s

Use metal 2x4s directly around the grill area to provide a strong heat barrier between the grill and combustible building materials. Wear gloves and invest in a decent set of tin snips when framing with metal. Also, keep normal frame rules in mind – no more than 16in apart on center. To aid with stability and weight, install pressure-treated 24 supports directly beneath the two centerpieces, spanning across.

Step 5 – Inside the Metal Supports, Fire Retardant Insulation was Added

We put insulation within the metal studs to guarantee a sturdy heat barrier. The metal framework was finished once the top pieces were inserted and fixed in place.

Step 6 – Using Pressure-Treated Timber, Frame the Second Part

This part, like the previous, was constructed in sections and joined together. Before placing it in place, we also placed a concrete board at the rear.

To square everything up, use a level stretching between the two parts, shim it, and fix it to the deck using wood screws.

Step 7 – A Concrete Board was Used to Cover the Outer Surfaces

If you really wanted to go nuts with it, you could coat the entire thing in Redgard, but we were OK with the concrete board itself.

Step 8 – Include The Grill Venting

These vents serve as both output and intake vents. Because fire needs to breathe, these vents allow the grill to inhale and maintain the fire burning hot while exhaling any harmful gases that may otherwise pile up and combust. Proper ventilation is essential for maintaining a safe outdoor cooking environment.

Step 9 – Before Putting in the concrete board, provide extra insulation to the grill area

Before we put another layer of the concrete board around the interior of the grill area, we filled all the spaces with fire-resistant insulation. Except, of course, for the rear portion, where we installed the vents. That was left open for the reasons stated in the preceding paragraph.

Step 10 – Install the brick veneer face

After the mortar has dry, instead of using grout as you would on tile, apply legitimate brick mortar in between each brick in a similar method. We piped it into the gaps with piping bags, then ran along with it with gloved fingers.

To Wrap it Up

We were at a loss for ideas when it came to countertops. Even though the brick veneer saved us a lot of weight, we did not want to add thick concrete counters, and we also needed something easy to clean and low maintenance.

Many barbeque lovers like to have their grills installed as a portion of a larger outdoor kitchen set-up, alongside sinks and drawers. It is indeed a great way to save space and keep everything close. However, there is a hazard in keeping cabinets and doors made from flammable materials too close to a machine that generates high temperatures. You must provide some protection from the intense heat of the grill.

On the other hand, insulating jackets can give you that protection from combustible materials like wood. They are aimed to absorb some of the heat and separate the grill from the rest of the furniture. Not every kitchen needs it, and some brands create grills with their own form of insulation. With that said, the odds are good that an insulating jacket will provide the necessary shielding for your kitchen.


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