A custom BBQ grill can be the crown jewel of an outdoor kitchen. With so many options for size, shape, fuel source and special features, a custom-built grill truly lets you make it your own. But who are the top manufacturers crafting these status-symbol grills? While there are many great mass-produced grills on the market, the companies that offer true customization stand apart.

Custom Grill Manufacturers to Know

Hearthstone

Since 1980, Hearthstone has hand-crafted custom hearths, grills, and outdoor living products at their facility in Morris, Illinois. Each Hearthstone grill is made to order, allowing you to select the size, shape, materials, fuel type, color and features.

With over 40 years experience, Hearthstone is one of the most established names in luxury custom grills. Their modular construction allows for endless customization, and their focus on quality materials and craftsmanship ensures your grill will last a lifetime. From high-end residential to commercial applications, Hearthstone grills deliver exceptional performance and timeless style.

PGS Grills

Based in California, PGS (Professional Grilling Systems) has been designing and fabricating custom grills since 1998. Each PGS grill starts with a consultation to understand the client’s needs. Using 3D design software, they map out the grill specs before beginning fabrication.

PGS offers an incredible range of options, from portable cart units to elaborate multi-burner built-ins. Their grills feature commercial-grade stainless steel construction and top-notch components. For unmatched heat and control, they integrate both infrared and convection burners. Known for their craftsmanship and customer service, PGS creates grills to meet their client’s exact needs.

Kalamazoo

Bringing over 100 years of sheet metal experience to grill-making, Kalamazoo takes a hyper-customizable approach. Their grills begin with a base model then integrate specialized features to meet each client’s vision.

Based in Michigan, Kalamazoo fabricates their grills from heavy-gauge stainless steel for durability and performance. They offer an enormous range of sizes and configurations, from 24” portable models up to massive 60” built-ins. From gas to charcoal to combination fuel, Kalamazoo grills deliver serious cooking capability. Their hybrid gas/charcoal models allow cooking with either fuel.

Fire Magic

With roots dating back to 1937, Fire Magic has been handcrafting luxury grills for generations. Based in California, their focus is on delivering exceptional performance through quality construction and engineering. Fire Magic builds each grill to order, offering a high degree of customization.

From minimalist modern designs to elaborate outdoor kitchens, Fire Magic can create a fully customized grilling experience. They offer an extensive range of grill bodies, carts, cabinets, side burners and more. With precise computer-controlled manufacturing and hand-finished detailing, Fire Magic combines technology and craftsmanship.

Twin Eagles

Since 1997, Twin Eagles has built an reputation for innovative and high-performing grills. Based in California, their engineers strive to integrate the latest technology into every grill. Twin Eagles offers an array of options for fuel types, burner configurations, sizes and features.

Each grill body and cart or enclosure is built from heavy-gauge welded stainless steel for durability. Twin Eagles is known for their Rumford-style burners, which optimize heating and flavor. From portable cart units to stunning built-ins, their grills deliver versatility through customization.

Design Considerations for a Custom BBQ Grill

Creating your dream custom grill means making decisions about the size, features, materials, fuel type and more. Here are some key considerations as you design your custom grill:

Size

How much total grilling space do you need? Large primary cooking areas allow for handling multiple foods at once. Warming racks, side burners and storage areas add functional space. Measure your intended location and consider your grilling needs and lifestyle.

A 3-burner gas grill with 400-500 sq. inches of primary cooking space is a versatile mid-sized option.
For large gatherings and parties, a 4-6 burner grill with 700+ sq. inches may be ideal.
For smaller patios, a compact 2-burner grill with 300 sq. inches can suffice.

Burners

The number and configuration of burners affect heating power and how you can use the grill space. More burners allow for indirect and zone cooking.

2-burner grills have a simpler rectangular shape while 3+ burners allow for more flexible U and L-shaped configurations.
Adding an infrared back burner expands cooking options.
Consider singletier and multitier grilling zones to enhance versatility.

Fuel Type

Gas, charcoal or combination? Each fuel type has pros and cons to consider.

Gas

Clean, convenient and simple to control heat. Natural gas offers an endless fuel source.
Delivers quick, even high heat perfect for flash searing.

Charcoal

Provides authentic smoky barbecue flavor many prize.
Managing temperature by adjusting vents takes practice but allows smoking and indirect cooking.
Requires purchasing and storing bags of charcoal.

Combination Grills

Offer the best of both worlds but come at a higher cost.
Allow cooking with gas, charcoal or both.
Enable smoking on one side while grilling direct heat on the other.

Materials

Constructing the grill body, flame tamers, grates and more with quality materials is crucial for durability and performance.

Stainless steel is ideal for grill bodies and components. Opt for 304 grade or higher.
Cast iron grates withstand intense heat while delivering excellent searing.
Ceramic flame tamers prevent flare-ups and vaporize drippings for flavor.
Double wall stainless construction resists discoloration and maintains heat.

Special Features

Consider which specialized options would enhance your grilling experience:

Infrared burners amplify searing heat to lock in juices.
A rotisserie burner offers slow roasting capabilities.
Smoker boxes introduce wood chip flavors when smoking meat low and slow.
Interior grill lights provide visibility for nighttime grilling.
Side burners allow preparing sauces and sides while grilling.

Framing

The cabinetry, cart, enclosure and countertops drastically affect the grill’s functionality and visual appeal.

Stainless steel cabinets offer a sleek built-in look.
Tile, stone or granite countertops provide an elegant outdoor kitchen space.
Portable carts allow flexibility in placement.
Insulated jackets improve heat retention in colder climates.
Doors, drawers and shelves increase storage capacity.

The Process of Ordering a Custom Grill

Once you settle on the specs of your dream grill, the fun of bringing your vision to life begins. Here is an overview of the typical custom grill ordering process:

1. Consultation – Discuss needs and options with a grill expert to finalize your ideal specifications.

2. Quote – Receive a quote detailing the grill’s materials, features, pricing and lead time.

3. Approval – Give approval for the grill order and provide any deposit required.

4. Fabrication – Your grill heads into the manufacturing queue for crafting, which typically takes 4-8 weeks.

5. Inspection – Thoroughly inspect your completed grill before packaging. Request any final tweaks.

6. Shipping – The grill ships to your location. Professional local delivery and setup is ideal if available.

7. Installation – For built-ins, the framing and countertops are finalized around your grill.

8. Grilling! – With grill assembly complete, it’s time to fire it up and start enjoying your new custom grill masterpiece.

Cost Considerations for Custom Grills

Having a grill uniquely built to your specifications comes at a price. Here are some factors that influence the cost of custom grill projects:

Size – The overall grilling area and number of burners substantially impacts cost. Larger grills require more materials and labor.
Fuel Type – Combination grills with gas, charcoal and infrared burners are more complex and expensive.
Materials – Commercial grade stainless steel construction elevates cost compared to powder coated steel.
Special Features – Adding infrared burners, interior lights, side burners, cabinets and more increases price.
Build Quality – Hand-crafted models from top brands using commercial-grade components command higher pricing.
Framing – Stainless or brick cabinetry, stone countertops and integrated storage raise costs but provide superior longevity.
Shipping Distance – Getting a grill from the manufacturing facility to your location adds expense.

For a high-end custom grill built to your exacting specifications, it’s reasonable to expect an investment of $5,000 to $15,000 or more. The craftsmanship and materials make it a long-term investment that enhances outdoor living for years to come.

Custom Grill Design Inspiration

Here are some stunning examples of custom BBQ grills to provide inspiration:

Hearthstone Custom Gas Grill Island

This elegant Hearthstone grill island features custom cabinetry, granite countertops, ample storage and top-notch components. The built-in grill body has three main burners plus an infrared back burner. The double access doors and drawers create a built-in look.

Kalamazoo Hybrid Grill and Smoker

This unique Kalamazoo grill includes a gas grill side and charcoal/wood smoker side. The two compartments allow for direct and indirect cooking options. The infrared burner provides intense searing heat. The upper cabinet conceals the propane tank.

PGS Custom Portable Grill Cart

Fabricated entirely from stainless steel, this freestanding PGS grill cart provides excellent portability. The grill body integrates commercial grade burners, grates and controls. The side shelves and doors offer ample prep space and storage.

Twin Eagles Built-In Grill and Cabinetry

With sleek stainless and black porcelain enamel finish, this Twin Eagles grill is integrated into an elegant built-in cabinet. The multi-tiered burners, infrared zone and accent lighting take grilling to the next level.

Fire Magic Custom Island with Columns

Creating an outdoor room, this Fire Magic grill island features Corinthian columns, tile countertops, grill body lighting and a power burner for intense infrared heat. The double access doors provide abundant storage.

Frequently Asked Questions About Custom Grills

What are the different fuel types offered for custom grills?

Most leading custom grill manufacturers offer options for either natural gas or propane fuel, plus many also provide charcoal grills and combination gas/charcoal models. High-end gas grills integrate both standard burners and infrared burners.

What determines the price of a custom built grill?

The size of the primary grilling surface, materials used in construction, fuel types, special features, framework and cabinetry all contribute to the price of a custom grill. Handcrafted construction from top brands commands a premium price.

How is the quality of a custom grill superior to a mass-produced model?

From the gauge of the stainless steel to the quality of internal components, a custom grill is built to higher standards. The materials and construction are designed for commercial durability, not home use. Precise hand-finishing also enhances quality.

How long does it take to get a custom built grill?

After finalizing your design specs, expect a lead time around 4-8 weeks for fabrication. Some complex builds with extensive cabinetry may take 10-12 weeks. Timelines can also depend on demand at the manufacturer.

What special features can be added to a custom grill?

Popular options include infrared burners, ceramic flame tamers, accent lighting, smoker boxes, rotisserie kits, side burners, premium thermometers, cabinet insulation, wood storage and more.

Do custom grill manufacturers offer design expertise?

Yes, most leading custom grill brands have experts available to consult about selecting the ideal size, features and options to match your space and grilling lifestyle prior to placing your order.

Let the Grilling Begin!

The attention to detail and high-performance capabilities of a custom-made grill make it a truly exceptional investment. While the process requires more time, effort and money compared to buying an off-the-shelf grill, the ability to get your dream outdoor cooking machine crafted to your exact specifications is worth it. A custom grill seamlessly blends form and function to enhance flavor and ambiance for many years of grilling enjoyment.

With some design inspiration in mind, reach out to manufacturers like Hearthstone, Kalamazoo, Twin Eagles, Fire Magic and PGS Grills to begin your journey toward the ultimate custom BBQ grill. Take time to thoughtfully consider all the possibilities so your grill perfectly matches your needs and style. Your taste buds will thank you!

Conclusion

The process of creating a custom grill allows you to integrate specialty features and quality materials that take backyard grilling to the next level. An investment in a customized grilling centerpiece fabricated by experts like Hearthstone, Kalamazoo, PGS or others offers exceptional performance, durability and versatility. With professional design consultation and hands-on craftsmanship, you can bring your unique grilling vision to life. A custom grill represents the pinnacle of backyard cooking, turning any meal into an occasion.

Who Makes Custom BBQ Grills