AB Courtyard Collection Weekend Project - BBQ Grilling Station How-to Sheet #290

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Building an AB Courtyard BBQ Grilling Station
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Build a BBQ Grilling Station with the AB Courtyard Collection in a weekend. This project demonstrates how to build on a hard, level surface, such as concrete or pavers. To build on soil, you must create a foundation pad. (Refer to How-to sheet #220 for more information on alternative foundations.) The dimensions of this BBQ grilling station used in this example are 36 in. H x 36 in. D x 87 in. W (0.9 m H x 0.9 m D x 2.2 m W) using a 39 in. (1.0 m) wide grill. To build using a different size grill, see Figure 8 for information on other grill widths.
Step 1: Build the First Post/Pillar Mark out the location of your grilling station. Draw an 87 in. (2.2 m) minimum guideline where the back of the BBQ grilling station will be constructed. Place the first Corner Block on the guideline where you want to begin. Place 3 more Corner blocks and 2 AB York blocks (Figure 1).		Step 1
Figure 1: First Post/Pillar Base Course Pattern		Step 1
Use a square to line up the blocks to ensure your post/pillar is square. Remove the raised ring on one of the AB York Blocks using a hammer and chisel. This will provide a flat surface for the next course of blocks. On the second course, place 4 Corner blocks so that they offset the blocks beneath them. Split an AB Dublin end-split block and place the large piece with the raised rings facing down and the split side against the Corner block (Figure 2). Save the smaller piece to be used at the end of the wall panel.		Step 1
Figure 2: First Post/Pillar 2nd Course Pattern		Step 1
Step 2: Build the Wall Panel Begin the wall panel by installing the first 2 courses at the same time, using the patterns shown (Figure 3), or one you have chosen. In this example we are alternating between AB Dublin and AB York blocks. Building the first 2 courses at the same time will ensure that the blocks line up properly. End the base course of the wall panel with a Corner block. End the second course of the wall panel with the remaining small piece of the AB Dublin end-split block used on the post/pillar (Figure 3).		Step 2
Figure 3: Wall Panel Course Patterns		Step 2
Step 3: Build the Second Post/Pillar Continue building the second post/pillar by placing 3 additional Corner blocks and 1 AB York block as shown (Figure 4).		Step 3
Figure 4: 2nd Post/Pillar Base Course Pattern
Use a square to position the blocks. Remove the raised ring on the AB York block with a hammer and chisel. Build the second course of the post/pillar by placing 4 Corner blocks starting with the first Corner block against the small piece of the AB Dublin end-split block (Figure 5).		Step 3
Figure 5: 2nd Post/Pillar 2nd Course Pattern
Step 4: Continue Building Continue stacking courses by repeating Steps 1-3 until the desired height is achieved. This example uses a total of 5 courses, plus one additional course of 5 Corner blocks to each post/pillar. The wall panel is one course lower than the posts/pillars to allow for movement of the grill hood (Figure 6).		Step 4
Figure 6: Hood Movement		Step 5
Step 5: Finish Place Wall Caps on top of the wall panel by alternating the caps to keep a straight line. Secure the caps in place with masonry adhesive (adhesive optional). Choose a countertop material to fit your design (Figure 7). Set your countertops in place and check for level. Shims may be used if adjustments are necessary. Secure the countertops in place with masonry adhesive, (adhesive optional) move the grill into place and you are ready to fire up the grill!		Step 5
Figure 7: Countertops		Finished
Materials Needed: 39 in(0.99 m) Grill 50 Corner Blocks 21 AB York Blocks 12 AB Dublin Blocks 5 Wall Caps 2 Outdoor Countertop Material 24 in (600 mm) x 32 in (800 mm) 2 Tubes of Masonry Adhesive		Tools Needed: Square Measuring Tape String Line Level Hammer & Chisel Safety Glasses & Work Gloves
Want to see more? Click here to check out our extended video as seen on HGTV.

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