Monthly Archives: December 2011

Steel Frame Table for Primo Oval XL

I was fortunate enough to pick up a Primo Oval XL at a bargain of a price. Like many product specific accessories things can get pricy very quickly and purchasing a grill table specific for the Primo Oval XL was no different. Seeing that I was somewhat successful at piecing together a quick grill I figured I could brain storm a bit and design something myself.

Like before I had several concepts and decided to scout around to get further ideas for an all wood setup. Definitely glad that I did. Wondering through the isles of Lowe’s I stumble upon some steel frames (72″ H x 0″ W x 30″ D) and beams (48″ L). So I purchased two of the steel frames and six of the steel beams. They must have been on sale because at check-out the total cost for eight pieces was $40.79

I did notice that the steel frame looks slightly different from the photo they have on their website, not exactly sure but the part number matches.

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Build a Grill

We needed a grill and did not want to fork over the dough to purchase one that we really didn’t want. Especially for the purpose of grilling steaks, carne asada, pork chops, hotdogs or burgers. My sister had a George Forman grill which worked ok but it was messy and the juices always ended up spilling on the countertop. Not to mention I really enjoyed cooking out in the backyard on top of that I’ve since become a fan of charcoal grilling.

I had several concepts which I drew up and after some consideration I finally decided on a simple project using 2x4s along with disposable rectangular foil roaster baking pans and nonstick cooling racks/trays which served as the grill grate. My idea was to have a frame that would promote three grilling surfaces in a simplistic rectangular shape.

I picked up the (2×4) framing wood at Lowe’s and ended up using two (2x4x10) and one (2x4x8) boards. I had them cut the board into specific sizes asking the associate to mind the thickness of the blade in their cuts because the measurements were really tight. Here are the cuts and sizes.

  1. (2) – 33-5/8″
  2. (6) – 11-1/2″
  3. (8) – 12″
  4. (2) – 12-1/8″
  5. (2) – 8-3/4″
  6. (2) – 9-3/8″

SPACER

Using both of the 9-3/8″ and both of the 8-3/4″ pieces I nailed them together using 4″ nails after drilling tiny pilot holes and adding some wood glue. This made hammering a tad easier. The purpose of this unit was designed to evenly space the inner 11-1/2″ rails used in the main frame. Here is my mockup of the spacer.

MAIN BASE

Using both of the 33-5/8″ boards and four of the 11-1/2″ pieces I constructed the main base. Starting with one 33-5/8″ and one 11-1/2″. Holding the two pieces together with the longer piece outside of the shorter piece I drilled tiny pilot holes, added wood glue and nailed them together. I then finished the other side and nailed together the main rectangle frame.

Using the spacer I placed it into the main frame and then used it nail in one of the 11-1/2″ piece. Following the same tactic I used the spacer again and attached the final 11-1/2″ piece. At this point I have the frame with three holding components. The final steps I added the four 12″ pieces used as legs.

I attached the legs where the 33-5/8″ and 11-1/2″ pieces met using two 4″ nails and two 2-1/2″ nails.

SINGLE GRILL BASE

With the remaining four 12″ legs, two 12-1/8″ and two 11-1/2″ pieces I nailed together a single grill base.

ACTION SHOT

Here’s the final product in action.

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