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Rotisserie Plans

Be sure to read the Rotisserie Introduction too!

Materials

2.0-inch, 11 gauge square tube

Part #

Description

Qty

Length

#1

Main Upright Supports

2

5 feet

#2

Rotating Arms

2

4 feet

#3

Wheel Base Extensions, these serve to connect each end of the rotisserie

2

12 inches

#4

"L" shaped Attaching Arms

8

11 inches

#10

Center Connector

1

7 feet

2.5-inch, .188-inch wall thickness square tube

Part #

Description

Qty

Length

#5

Center Outside Connectors

2

6 feet

#6

Wheel Bases

2

4 feet

#7

Rotating Arm Width Adjustment Sliders

4

6 inches

#8

Rotating Arm Height Adjustment Sliders

4

3 inches

#9

Vertical Sliders

2

12 inches


Optional Two one-foot lengths of 2.5-inch square tube. Weld these to each wheel base so that the main upright supports can be removed for transportation and storage. See the Drawings page for details.

3.5-inch diameter, 3/16-inch wall round stock

Part #

Description

Qty

Length

#11

Large Round Tube

2

8 inches

3.0-inch diameter round stock

Part #

Description

Qty

Length

#12

Small Round Tube

2

8 inches


Note Wall thickness isn't critical here, just make sure that #12 can slide into #11.

5/8-inch threaded rod

Part #

Description

Qty

Length

#13

5/8-inch Threaded Rod

2

11 inches

1/4-inch plate

Make triangle shaped braces, and add wherever you feel necessary. See the Drawings page for details. Also, use some 1/4-inch plate or angle for wheel mounts.

Construction

Step 1

Cut all materials to length with a 14" chop saw. The $150 Milwaukee Chop Saw I used on this project struggled with the heavier material, especially the large round tube. You might want to pay your metal supplier to make as many cuts as possible.

Step 2

Drill all holes, except for the Vertical Sliders (#9), using a drill press and a 29/64" bit. Drill 5/8" holes in the Vertical Sliders for the 5/8" Threaded Rod. Because there are many holes to drill, I recommend an efficient method of clamping the material, such as one of those "Vice Grip" type clamps that mounts to the drill press. Don't forget to use a few drops of oil on the bit. This is one of the most time-consuming and boring parts of the project. See the Drawings page for details on hole placement.

Step 3

Grind all cuts and holes until they are smooth and free of burs.

Step 4

Weld the Upright (#1) to the Wheel Base (#6). Repeat for the other Upright. I used a 220V AC arc welder with 6011 rod for all welds. 6011 rod is pretty messy, but fairly idiot-proof. A 240V MIG welder would've been ideal, but the last time I checked I didn't happen to have one. Darn! I was thinking about using my 110V MIG machine with flux coated wire, but the guys at the welding shop recommended against it. Weld penetration would have been iffy, plus I would've been bumping up against the duty cycle of the machine. Make sure that all pieces are aligned without gaps. Chamfer edges as necessary to ensure good weld penetration.

Optional To make the rotisserie more portable, I made the Upright (#1) detachable from the Wheel Base (#6). I did this by welding a 12" length of 2.5" square tube to the Wheel Base (#6). Corresponding holes were drilled into this length of tube and the Upright (#1) so that they can be bolted together.

Step 5

Weld the #4 pieces to form the "L"-shaped attaching arms. Repeat for the other three brackets.

Step 6

Weld the #7 and #8 pieces to form the Horizontal Sliders. Align so that #8 is flush with one side of #7. Repeat for the other three Horizontal Sliders.

Step 7

Weld the 5/8" Threaded Rod to the hole you drilled in the Vertical Slider (#9). Alignment is critical, and don't position the Threaded Rod too deeply in the hole, or else the Vertical Slider will not be able to travel up and down on the Upright (#1). Repeat for the other Vertical Slider.

Step 8

Weld the Large Round Tube (#11) to the Vertical Slider (#9). Center the tube so that the 5/8" Threaded Rod is in the center, and rotate it so that the hole for the Rotating Arm Set Screw is on top. Repeat for the other Rotating Arm. It's not possible to weld #11 360 degrees, so I added braces to the top and bottom of the Large Round Tube just to make me feel better.

Step 9

Weld the Small Round Tube (#12) to the Rotating Arm (#2). Center the tube so that 5/8" hole is in the center. Repeat for the other Rotating Arm.

Step 10

Weld a 5/16" nut to the Large Round Tube (#11) for the Rotating Arm Set Screw. Run a bolt through the nut to make sure that it is centered over the hole. Repeat for the other Large Round Tube.

Step 11

Weld 5/16" nuts to the Center Outside Connectors (#5).

Step 12

Weld wheel mounting plates to the Wheel Bases (#6), and attach pneumatic caster wheels to the Wheel Bases.

Step 13

Assemble the Rotisserie. One person can do it, but two makes it a lot easier.

Note You'll notice a bit of "slop" in the way all of the parts fit together. Don't worry about it. The unit becomes much more rigid once its stressed. Plus, this "slop" makes it easier to fit everything together.

Step 14

Disassemble the rotisserie. Remove any surface rust, clean with lacquer thinner, and paint with a couple of spray cans in your favorite color.

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