Measure your stand-alone grill and add a 1/2 inch to 1 inch to the length and width.
Design your barbecue island on the grid paper using the scale of 1 inch being equal to 1 foot. The grid of the grid paper is made up of 1-inch squares. There are several things to take into consideration as you design; the placement of the fuel or charcoal, the size of the area where the island will be placed, storage and extra components, such as sinks. Choose the shape of the island and draw the grill first, then draw the island around the grill.
Measure the design and determine how many studs you need. For example, a rectangular island with an extra 2 feet on either side of the grill needs a vertical stud on all four ends of the grill, one vertical stud for each corner of the island, four horizontal studs the length of the island and eight horizontal studs the width of the island (four for the outer corners and four to fit around the grill.
Lay the metal stud with the “U” shape side up on the work bench or saw horses and mark the stud with a marker where the need to be cut. Cut the sides of the “U” downward to the base. Slide the cut end of the stud to the edge of the sawhorse or workbench and press down. The cut sides separate, creating a gap to cut the bottom of the studs. Repeat for all the lengths of studs you need.
Examine the edges of the cut studs and make sure that they are square. Trim any edges that are not square.
Create the base of your island frame. Lay two studs that are the length of the island on the ground, and place two width stubs on the ends to connect the length pieces together. The “U” shape of the stud faces inward. Clamp the two studs together to hold them in place. Use a self-taping screw and a drill to drill one screw in each corner one-fourth of an inch from the end of the frame. Repeat to create the top of the frame.
Flip the bottom frame piece upside down so that the screws are on the bottom.
Use a piece of the “U”-shaped stud to mark the width of the stud at each point where a vertical beam will be placed.
Cut out the width of the vertical stud at each location on the top and bottom frame pieces. Slide the vertical studs into the bottom frame and attach them with self-taping screws one inch from the edge on both sides. Use the framing square to ensure the frame is a 90-degree angle.
Slide the top of the frame over the vertical studs, and attach them to the top in the same method as the bottom. Check the angles with the framing square.