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Meathead's dream
I have never built a grill, smoker, or pit from scratch, but if I did, here's how I'd design it:
 It needs a solid slab so it doesn't sink.
I'd want something big enough to handle a big party and a 200 pound hog, but adjustable so I could cook a few burgers, too. So I'd design a large concrete block or brick rectangle about 8' long, 4' deep, and 3' high. There would be two removable partitions so it can be divided into three separate cooking zones. In one zone I could cook small quantities efficiently, another could be used as a warming oven, an the third could be used to burn logs down to coals or it could also be used as a bread and pizza oven.
Each partition needs a separate lid so it can be closed for roasting, smoke roasting, or baking. Each partition would need its own damper for letting in air, and a vent for letting out smoke.
The food grates for each partition would need to have adjustable height so steaks could be lowered near the coals for searing or raised for low and slow direct or indirect cooking.
The three ash grates should be above ground so air can flow beneath the coals and for easy ash removal.
There needs to be a large work surface nearby and storage for tools.
There should be tables and seating nearby.
The whole shootin' match needs to be under a roof for all weather use. That roof would need a chimney so smoke and carbon monoxide would not collect under it.
While I'm at it, why not enclose the whole thing with screen to keep out mosquitos and flies.
Anybody out there want to draw up some plans?
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Solar ovens
In the past few years several solar oven manufacturers and designs for home made units have appeared. They are perfect for the poor, for disaster relief, and for wilderness cooking. Some links:
Solar Cooking
Solar Oven Society
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Building Your Own Grill or Smoker
Handy with tools? Too cheap to buy a cooker? Can't stand wasting money on the garbage sold in the stores? Build your own. The internet has a number of designs and ideas for the do-it-yourselfer, whether you want to build a grill, hog cooker, or smoker.
Grills
7 tips on building a brick grill. This article helps keep you away from the, ahem, pitfalls.
From HGTV. Home & Garden TV has step by step instructions.
Old Fashioned Backyard Brick BBQ Pit With Wood Storage Rack. That's it in the picture at the top of the page. Tis page has detailed instructions, day by day guidance, and a complete parts list. The design appears to be from the 1950s.
Bob Villa rebuilds a clunker. A video of how Vila's mason makes an old clunker into a nice grill. He discusses the correct cement mix.
Lexington Collection's Wide World of Pits. A gallery of home made grills and smokers from Dave Lineback.
A simple open brick grill. With wood storage.
A concrete block design. Uses a fireplace insert.
An open grill with a car jack The jack raises and lowers the food.
A large open air pit. Comes close to my dream machine. This link is to a pdf.
Barbacoasluna.com Videos. This company has videos of their designs on YouTube. There are some great ideas here.
Buy the plans for this beautiful brick grill.
Barbecue Building Book a Sunset gardening & outdoor building books
Smokers
Wilber. A great brick smoker with photos and detailed plans.
Slideshow. Here's a slideshow of an nice brick smoker being built.
Combination Grill and Smoker Plans by Tom Henry. You can buy the plans for this very nice looking design.
Whole hog cookers
From Jim S. 24 photos of a concrete block whole hog pit and how to use it.
Dan Gill's classic North Carolina pit. Made from concrete block.
Bill Tolbert's clever innovations. Tolbert took the basic concrete block hog cooker and used scalloped garden retaining wall material to hold the hog on rebar. He also used angle iron to make a window for adding coals.
Joe Davidson's Video. A simple design on video.
Pizza ovens
Wood fired pizza oven. Made from cinder block and clay with wood storage. Click to download a pdf.
A slideshow of a well engineered pizza oven.
Another detailed slideshow of a large pizza oven. Man, this guy's gotta love pizza.
Parts
H.C. Muddox. Sells special high temp fire bricks and tubes.
On my Charcoal Grill Buying Guide page there are links to some fireplace inserts that would work nicely on outdoor systems.
Ugly Drum Smokers (UDS)
The UDS is a 55 gallon steel drum converted into a grill and smoker. It a popular topic on barbecue message boards. Many have special topical sections devoted to their design and construction with photos. Some pretty clever engineering and cutting and welding can be seen there.
The BBQ-Brethren.com has several pages devoted to the topic. They aptly label this as "the mother of all UDS threads. All information you will need to build a UDS is in this thread. use this, and a search of the forum for UDS and you will find a wealth of information."
TheSmokeRing.com has another thread on UDS. Here's another good thread there.
This page was revised 7/18/2010
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Read this before posting a comment please:
1) If you are looking for info, please use the table of contents or the search box, at the top of every page.
2) Don't ask me any questions that involve temp or time unless you tell me that you are using a digital thermometer! Bi-metal dial thermometers are often off by as much as 50°F! If you are not using a good digital you have no idea what the temp really is so I can't help you. If you are still using a dial thermometer, please read this article about thermometers, then buy a good digital, and then, if the problem persists (chances are it won't), hit me with your questions. Then, please tell me everything I need to know to answer your question. Like the type of cooker you are using. Remember, I am not a mind reader.
3) Please don't ask me "What grill (or smoker) should I buy?" Read my Buyer's Guides and the buying checklists and follow the links. I've shared just about everything I know. Pay attention to the awards I have given my faves. I cannot pick the right cooker for you any more than I could pick the right car or spouse for you.
4) If you have problems posting with Internet Explorer, please read this. If problems persist, send me a note.
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AmazingRibs.com Best in BBQ Gold Medal Winners
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The Smokenator: A Necessity For Weber Kettles
If you have a Weber Kettle, you need the amazing Smokenator and Hovergrill. The Smokenator turns your grill into a first class smoker, and the Hovergrill can add capacity or be used to create steakhouse steaks. Click here to read more.
ThermoWorks Pocket Thermometer - No More Guessing
A good thermometer is why I never serve overcooked or undercooked food. This one has a very thin tip with a tiny thermocouple so it gives an accurate reading in just six seconds. I cannot recommend it more highly. It will improve your cooking overnight and pay for itself in a hurry. And it is inexpensive. Click here for more about thermometers.
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