From Derrick Riches,
Your Guide to Barbecues & Grilling.
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Charcoal grills are great for flavor but do require more attention and preparation. If you choose to go with a charcoal grill for your outdoor kitchen you will probably end up doing a little more customization. Like I said, there isn’t a lot out there in the way off a charcoal grill insert. You will need to rely on cooking grates that you can buy of the shelf or have someone make them for you. A metal manufacturing company or foundry should be able to provide you with custom grates that fit your specifications.

When planning for a custom charcoal grill you need to think about the features you will what to have available. For instance, do you want a lid for roasting foods? Do you want a rotisserie? If you are going to have someone build the metal components for your grill you will need to have the grill unit planned out before you start planning the enclosure.

Of course on the most basic level you will need a pair of metal grates for your charcoal grill. One grate to hold the coals and the other for the food. You also need airflow. When it comes to charcoal cooking, airflow is very important. Air needs to be able to travel up through the burning coals and out, over the food grate. This means sufficient open space to get oxygen into the fire. You also need a space to catch falling ash that is completely fire proof. You don’t want burning embers falling on your feet or your patio.

The charcoal grill area needs to be lined in firebricks. These are the same kind of bricks you would use in a fireplace. Since the firebricks can become very hot they need to sit overtop of another layer of brick or block to insulate the area where the fire will live. The construction of the brick lining should also include the mounts or racks for the metal components.

Give the metal parts some thought when planning you charcoal grill. You might want a cooking grate that is adjustable to give you that extra level of cooking control. A crank driven adjustment would allow you to change the level while cooking and give you the ability to sear close to the flame and rise up, away from the fire to finish foods off. If you want to use a rotisserie, there are many units on the market, you need to make sure that you can mount it properly and that it is stable enough to spin any food you might want.

When it comes to the metal components you need to choose a metal that will last. Cast iron is great for cooking but will rust if not properly protected and cared for. For this reason a cover or lid will be very beneficial. When looking into fabricated metal parts, ask about a stainless steel lid to cover the grilling area.

One great thing about a charcoal grill is that you can also use it as an outdoor fireplace if you design it to serve this purpose. By creating a front opening to your charcoal grill you can let your fire provide light and heat for outdoor parties and gatherings. One thing to remember however is that you must be able to close this space to protect your griller from the heat.