Jerry's BBQ Project

How I built a killer BBQ from a cheap model (do not attempt!)
The first order of business was to find the right base model.  I chose a Char-Broil at Home Depot for $170.  It may sound expensive, but this was one of the cheapest gas BBQs there was.  When I put it together, I left the Char-Broil emblem off of the lid because why should I install something to advertise for them?  And this thing is a pile of junk anyway!  They should be prosecuted for selling such worthless crap...  but I digress.
The problems started as soon as I assembled it and fired it up.  The flames from the single 4" wide burner were maybe an inch high.  This means that what little heat there was coming out, was all in the center.  No even heat distribution and WAY underpowered.  The book on this model claimed "40,000 BTUs."  I doubt that the idiots at Char-Broil even know what BTU stands for.  I didn't measure it, but from experience, I could tell that it wasn't even 12,000 BTU.  On top of all this was a metal drip cover, that basically covered the flames.  This is basically the same thing as my gas oven (only with no power!).

So I started doing some research.  I removed the regulator.  This was, of course crimped on because they don't want schmucks messing with it.  After I cut the hose, the guys at the local hardware store crimped on a standard pipe thread joint so I could attach whatever I wanted.  The old regulator went in the trash (after I smashed it open to see what was inside, of course!).  So now, I should have had unregulated pressure.  Nope.  Still one inch high flames.  So I drilled out the jet on the left side and that was a little better, but still far from par.
I finally figured out that the problem lies in the connector to the tank.  Now a days they come like this.  Instead of the good old brass, left-hand threaded connector that used to come on every BBQ, they now all have this plastic right-hand thread connector that screws to the outside threads on the propane tank.  The issue with this is not right vs left thread.  The issue is internal to these connectors.

Look at the hole in the end of the brass.  The normal hole is less than 1/16" in diameter (this one shown here has been drilled out).  So, after discovering this major restriction, I started drilling the hole larger and larger.  This did produce some improvement (also remember that I have no regulator at this point).  At 1/8" I reached a point of diminishing returns because of more internal "safety" crap built into this fitting.  And, they make so you can't take it apart.
So I headed down to the hardware store to buy the old fashioned fitting.  Look at the size of that opening!  It's better than 5/16" ID.  That means an increase in the cross-sectional area of at least 21 times.  While I was at the store, I figured I would pick up this nice adjustable pressure regulator.  It makes for great adjustability, because the knobs for flame height on the BBQ are only slightly useful.  Plus, wide open on this thing is just that; no restriction.  I installed this setup, and BAM, I got all the flame and heat I wanted.
Next order of business was to spread the flame and heat out.   Remember that it only offers flames from a single 4" wide center burner.  Adding a grate and lava rocks allows great flame and heat distribution.
Now, let's check the performance.  Remember that the left side jet is drilled out larger than stock.  This means that the max flame height can be higher on the left.  Here's a nice initial shot in the day time.  Notice the flames are visible on the left.  The flames on the right are just below the lava rocks.  Also, remember that I can turn both sides down as much as I want, and I still have independent controls via the stock knobs.
So let's have some fun!  More power, more power!  This is not wide open, just kicked up a few notches.  Of course I don't cook like this, but I can use it to heat up leaf springs for bending, or perhaps do some metal forging!
So let's see what this thing looks like at night.  Nice looking, toasty warm BBQ; just about right for some fast grillin!
So, how much power can we get out of this at night?  Let's find out.  This is at about 85% full throttle.  It was hard to measure with the intense heat, but I think it's safe to say that the flames cleared 14" off the grill!  Not to imply anyone would want this, but hey, you know...  you gotta see what she can do, right?
Get this.  I figure I will go for FULL power.  So I go with throttle up and BAM, the front panel of the BBQ ignites...  I mean the outside of the BBQ; the front panel; where the knobs are, spontaneously bursts into flames a few seconds after I go to "full burner!"

Holy cow, I thought, as I stared at the flames on the OUTSIDE of my BBQ that now cleared 6 feet in the air.  I was deciding if I should take a picture, grab the fire bottle, or turn off the gas.  So I turned off the gas. :(

Sorry no picture of this since I wussed out and shut off the gas valve instead of toughing it out like a real man while I take a picture.
I thought about this for a while.  What in the heck burst into flames on the outside of my BBQ?  It couldn't have been the paint or the knobs.  Then I realized that it must be that the pressure is so high that not all the propane can escape through the burner holes (can you see me drilling larger burner holes now?  HAHA).  Anyway, because of this, the propone gas backed up all the way to where the jets meet the gas tubes.

There are some air inlets there.  The flame was coming out from these holes, which is right below the panel.  So now that I figured out what happened...  well, I HAD to do it again for a picture!  Only this time, I just maxed out the right side only (to be safe!).
And here it is on full burn (right side only).  Note the source of this "back blast" can be seen at the bottom of the control panel.  This confirms that it's backing up and coming out from underneath.  My hypothesis was correct.  Remember that this ONLY happens when I turn the pressure regulator up 100%.  Normally, I use it at about 30%.

I wish I had a picture when both sides were on fire...  wow, that was awesome!
So, as you can see, I have proven that I can build a killer BBQ for about $200 ($170 of the BBQ and the rest for the special regulator and fittings); and this can be done safely.  Imagine having the best BBQ you can get for that kind of money, using a few smart and safe tricks.

WARNING- DO NOT ATTEMPT ANY OF THIS!!!!  I AM WHAT YOU WOULD CALL AN "EXPERT" (just like those Mythbuster guys!).  You will of course, want to try this at home.  If you try anything with propane, make damn sure your life insurance is paid up...  and oh yeah, don't mention my name or this site!  You are on your own!  Serious note- this type of stuff can result in major damage, fire, injuries, and (easily) death.