re: Man Projects: Make your own Big Green Egg

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If I can find square pots, finding square grills to fit should not be aq problem.

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I've not completed it yet, just collecting materials, but here's my plan:

A large terra cotta chimney flue pipe. It's square and taller than a pot, and it can be cut with a masonry blade if needed. Enough fire bricks to loose lay as a base to set the flue pipe on. Four fire bricks can also be stood up on edge inside to create a ledge for a tray if needed (round terra cotta saucer or metal ). Holes will be drilled thru the side walls at different levels to insert two steel rods across for adjustable heights for the grill. May be plugged when not in use with wooden dowels.
The top (at this time of planning) will be 3/4 inch plywood with 2 "D" shaped cabinet type handles on top.

Heat source will be my propane tank and a modified burner to sit on the brick base. I will have a metal pipe extention to the burner to keep the rubber hose out of harms way.

I'm open to suggestions.

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I'm not exactly sure what you are talking about, but I don't know if you want to have wooden parts on the interior surface of the grill, especially if you are going to be burning at high temperatures.

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Not protruding into the inside. Just a thought to close any openings. May not be necessary. A hard wood plug should not be affected, and over time can be replaced.

A little off the subject of cooking---but could the pot and stand also be used as a fire pit to stay warm tailgating? Just wondering

I'm assuming since all the metal is outside of the ceramic, when it expands outward it will not put pressure on the ceramic. If the metal was inside the ceramic, it would crack the ceramic as it expanded at a faster rate. At least that's how I understand it.

Anybody try this yet?

You can regulate the temp by hooking up a 600 watt dimmer switch to a GFCI plug and connecting it to the hot plate. You just have to remember to disconnect the thermostat on the hot plate.