building a BBQ bench

Thinking of building a built-in bbq bench.

Hesitant to do it in timber because of all the cautions about distance from heat sources and all that, even though I believe it can be achieved if you're careful. Don't want to take the risk.

Was thinking of using 25mm x 25mm x 1.6mm square gal steel tubing cut to size and either welded or use those 'tap in' end-connectors.
Then I'll clad it in blueboard to add some stiffness/bracing, and render it or paint it, or tile it, or something...

Was just going to build two boxes (h:900 w:600 d:600) and screw them down directly onto my unfinished (outdoor) deck joists, before cladding them.

Whaddaya think? 25mm strong enough? 30mm better? 20mm ok?

Anything else to be aware of, or should it be fairly easy?
I've only ever worked with timber, so never tried steel.

Thanks! :)


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