Cardboard Model

Before cutting any metal, we first created a full-scale cardboard model of the barbecue to test the proportions. Making cheap models is a common design practice we do with our clients in order to reduce development cost and time, allowing us to refine concepts before committing to more expensive materials. Using the scaled-down dimensions of the F-35, we carefully cut and assembled the cardboard pieces, ensuring that all elements looked balanced and visually accurate. This step allowed us to make adjustments before metal fabrication, helping us perfect the design and confirm that the final build would capture the fighter jet’s distinctive shape.

CAD Drawings

We used CAD software to design each component of the barbecue, ensuring accuracy and a seamless fit. To maintain the correct proportions, we took the dimensions of a real F-35 fighter jet and scaled them down by a constant factor. This allowed us to preserve the jet’s overall shape while adapting it into a functional barbecue. Every detail, from the wings to the exhaust nozzles, was carefully drawn in CAD before being cut from metal, ensuring both precision and a striking final design.

Cutting The Fuselage

We started construction by selecting an empty fire extinguisher to serve as the fuselage of the barbecue. After carefully measuring its dimensions, we determined the ideal placement for openings, ensuring proper airflow and functionality. Using an angle grinder, we precisely cut out the necessary holes, shaping them to fit the design while maintaining the extinguisher’s structural integrity. This step was crucial in transforming the extinguisher from a simple metal cylinder into the foundation of our fighter jet-inspired barbecue.

Plasma Cutting

Next, we transferred them to a CNC-controlled Plasma Cutter to precisely cut each metal component. The Plasma Cutter allowed us to achieve clean, accurate cuts, ensuring that every piece matched the scaled-down dimensions of the F-35 fighter jet. This process was essential in capturing the sharp angles and sleek lines of the design while maintaining consistency across all parts. With the metal sections cut to perfection, we were ready to begin assembling the barbecue.

Welding

With all the metal components cut and prepared, we used MIG welding to join them together, ensuring strong and durable connections. This welding method allowed for precise control, helping us fuse the pieces while maintaining the barbecue’s clean, angular design. As we worked, we carefully adjusted heat and speed settings to achieve solid welds without excessive buildup. Once fully assembled, the structure was both sturdy and visually cohesive, ready for finishing touches like smoothing, painting, and detailing.

Angle Grinding

After welding the metal components together, we used an angle grinder to smooth out the welds, creating a clean and seamless finish. This step was crucial in refining the overall look of the barbecue, ensuring that the joints blended smoothly into the design.

Painting

Once the surface was prepared, we applied the three-tone color scheme using high-temperature-resistant spray paint. To achieve crisp lines and sharp transitions between colors, we carefully masked off different sections with tape, layering the paint to create a sleek, aviation-inspired finish that enhanced the fighter jet aesthetic.