Upcycling a LPG Gas Bottle into a Log Burner

A Creative Journey

Transforming a LPG Gas Bottle into a Log Burner

Upcycling a LPG gas bottle into a log burner is a rewarding project that sparks creativity. This process tests your skills and pushes your limits. Every step offers valuable lessons, from initial mistakes to final touches. Inspired after qualifying as a welder, I aimed to improve existing designs. My goal was to build a better, more practical log burner from scratch.

Rethinking the Log Burner Chimney

The first challenge was designing a better chimney system for the gas bottle log burner. Fixed chimneys welded onto the body caused transport issues. Short chimneys limited smoke extraction. I designed a detachable chimney for easier transport and improved smoke flow. Initially, I planned two interlocking tubes that could be broken down and stored within the burner.

Designing a Detachable Gas Bottle Log Burner Chimney

I carefully researched tube dimensions, thickness, and weight. The removable chimney seemed ideal on paper but was difficult in practice. Heavy weight and welding made the design inefficient. I chose a pre-made stainless-steel detachable chimney instead. Using exhaust pipe sections, I created a strong socket with flux-core MIG welding, reinforced with stick welding. The chimney now functions perfectly, proving patience pays off.

Improving Stability: Gas Bottle Log Burner Legs

I then focused on the burner’s support system. Many designs rely on the bottle’s support ring, which sits too low. This makes loading logs difficult and poses heat risks. Using CAD software, I designed a height-adjustable leg system. I experimented with a modular design, with three evenly spaced legs at 120° for stability.

Building Robust and Adjustable Legs

Precise measurements ensured stability. The final two-tube system slid into each other and secured with an 8mm bolt. Silicone shoes improved grip and protected surfaces. This subtle, yet effective detail enhanced both functionality and appearance.

Making the Gas Bottle Log Burner Door

Cutting the door seemed simple but faced challenges. Creating a curved template was easy, but fitting the stainless-steel mesh was tricky. Working with thin mesh and flux-core wire required finesse. Too much heat melted the mesh; too little caused weak welds. After trial and error, I perfected my technique, tacking beneath and reinforcing above. The hinge-mounted door now operates smoothly and feels professional.

Final Finishing Touches on the Gas Bottle Log Burner Door

Once the main structure was complete, I added details. The handle, inspired by a gate latch, used a stainless-steel spring handle and a round bar mounted on a small plate. A tiny angle iron stop prevented over-swing. Inside, I welded brackets from angle iron for a stainless-steel griddle. Everything was aligned for stability and a level surface.

Restyling and Final Coat

I removed the original paint using a grinder with a paint-removal disc. After sanding with 80-grit paper, the raw metal revealed a rugged look. Applying high-temperature black stove paint gave a professional finish. The result is a durable, stylish LPG gas bottle log burner.

Lessons from Upcycling a LPG Gas Bottle into a Log Burner

This project taught me valuable lessons in problem-solving and creativity. Adapting ideas that didn’t initially work led to better solutions. I grew as a builder and engineer. This experience has fuelled my desire to take on more challenging future builds.