DIY projects offer a great sense of accomplishment. Better yet, they save money when done correctly the first time! Constructing an outdoor kitchen yourself has several benefits. It is cost-effective, customizable, and gives you the freedom to add as many different cooking appliances as you like, expanding your grilling horizons. You can also start with a barbecue island kit to make it much simpler. These are easy to build, save time and money, and simplify design planning due to their modular nature.

So, where does the grilling come into play? The answer lies in the seamless integration of a built-in gas grill, which fits perfectly into a pre-cut slot on a barbecue island kit. This slot is referred to as the “cutout,” a term that comes from the need to appropriately measure and cut away to make room for the grill insert. Depending on whether you use a ready-to-assemble island or build the island yourself, this may happen at different stages of the process.

Before getting started, it’s important to read your owner’s manual for your grill and unfinished island (if applicable) and follow all manufacturer’s instructions. This is especially crucial for clearance to combustibles and ensuring that you won’t void your warranty. Now that we have that taken care of, let’s go through the steps to making your grilling dreams come true.

Steps to Measuring the Cutout for Your Built-In Grill

So, you’ve got your BBQ island (coming together nicely, isn’t she?). You might even have your grill! Here’s how you come that much closer toward grilling paradise:

  • Built-In Grill Cut Out Dimensions Diagram

  • Step 1: Measure the Width — Find the “Cutout Width” (marked “A” on the diagram). This is the width for the slot of your grill head. Your grill will sit on the ledge on either side of this cut as you slide it into place. To ensure a perfect fit, figure out exactly where you want your grill to go, locate the center-point, then measure out half the width to either side. Easy enough, right?

    Step 2: Measure the Depth — Find the “Cutout Depth” (indicated by “B” on the image). This determines how far back the grill will sit within the island. Measure from the front edge of the island to the point where the back of the grill will align. Balance is important here: you don’t want it jutting out too far, and you also don’t want it sinking too far in.

    Step 3: Measure the Height — Find the “Cutout Height” (C). This is how far down the grill head will sit once in place. Traditionally, this depends mostly on the height of the control panel and whether your chosen grill head boasts a drip pan or other features that extend its height. Very important: if your countertop isn’t installed yet, don’t forget to factor in that additional height! Additionally, cutout height dimensions almost always include a small gap under the grill for airflow. It is essential not to cover this up.

    Step 4: Make the Cuts — Once all measurements are made, you’re ready to start making those cuts! Remember to always measure twice and cut once to ensure you have all the proper measurements. One important tip to be mindful of: it’s best to wait until your gas grill gets delivered. Dimensions can be found online, but we encourage you to measure everything in person just to be sure. Also, if you end up going with a different grill for some reason, you won’t have the proper cut outs.

  • Built-In Grill Cut Out Dimensions Diagram

What About Insulated Grill Jackets?

If you’re building your barbecue island out of any kind of combustible material, an insulated grill jacket is a must. This goes for every cooking appliance, not just grills. Our Insulated Grill Jacket Buying Guide can provide more information and set the record straight on whether you need one.

Bring Your Outdoor Kitchen Dreams to Life

Now that you have the know-what, get the know-how! Need a helping hand? Our Free Design Services (a $500 value!) is an incredible support resource that can help you through every step of the process with high-quality renderings. If you have any questions before you get started on this journey, give our experts a call at (877) 743-2269 and they can give you answers to anything you need to know.