Bourbon Trail Grillworks is a custom grill manufacturing initiative from One Time Fabrication is a family-owned start-up located in Western Kentucky USA. We specialize in custom-made Santa Maria Grills, industrial parts, components, and more.
2019-Present Day
One Time Fabrication was started in 2019 as a hobby to help support our family. As a machinist by degree, I enjoy fabrication work as a hobby. One day I decided that maybe I should try my hand at a small business to earn some extra income so my wife could spend her days at home raising our newborn. We started with an 18’x18′ shop and a small generic CNC plasma table like most. After about 6 months of 14-16hr days, we were becoming more successful by the day and running out of room.
We decided to build a much larger workspace and add some more state-of-the-art industrial equipment. We purchased a plasma table from one of the best companies in the industry (JD squared), along with a few other machines and equipment. Now we are able to produce the best quality products possible. With all of the added space, we can handle a much larger volume of orders without it affecting the quality for the consumer. For instance, the old 18’x18′ shop is right next door and still in use, it has become nothing but a large paint booth so as orders are drying we can still continue to work on new incoming orders.
We strive to have the fastest turnaround times possible with all of our custom orders! We take pride in our work here at One Time Fab trying to put a smile on every face that receives a gift from our shop. I think it shows in our reviews and our repeat customers. We would like to thank each and every person that has supported our small business in getting us this far because this started as just a dream and it is quickly becoming a reality, and for that, we couldn’t feel more blessed.
We try to add new pieces to our shop weekly but if there is something that you are looking for that we are not offering please reach out to us because odds are we can take your ideas and turn them into exactly what you’re looking for and we would be glad to help!
Our Santa Maria Grills
The popularity of our Santa Maria Grills has allowed us to shift our focus a bit as we now offer a complete line of grills and grill accessories in our online store. Our grills are hand-made to the highest level of quality and craftsmanship, and will definitely be the center of your barbecues and outdoor parties. We offer many models and sizes to suit your needs and budget. Click here to learn more about our Santa Maria Grills, grill options, and accessories.
The Fiery Legacy of Santa Maria Grills: Handcrafted by One Time Fabrication with a Kentucky Bourbon Trail Twist
Imagine a fire crackling in the open air, its warmth and aroma beckoning friends and family to gather around. Now picture a massive cut of tri-tip sizzling over red-hot coals, its juices dripping onto the fire, sending up plumes of flavorful smoke. This, my friends, is the magic of the Santa Maria grill, a culinary icon rooted in tradition, transformed by innovation, and fueled by passion.
The Origins of Santa Maria Grills
The story of the Santa Maria grill begins in California’s Central Coast, specifically the Santa Maria Valley. In the 19th century, Spanish ranchers, or vaqueros, in the region began grilling large cuts of beef over open flames to feed hungry crowds after long days of cattle herding. The meat was seasoned simply with salt, pepper, and garlic, and cooked on adjustable iron grates over red oak wood—a native hardwood that imparts a distinct smoky flavor.
The design of the Santa Maria grill reflects its practical origins. A wheel mechanism allows the grill grate to be raised or lowered, giving the cook precise control over the heat. This adaptability was essential for cooking different cuts of meat to perfection, a hallmark of the technique that endures today.
Famous Chefs and the Santa Maria Tradition
Modern chefs have embraced the Santa Maria grill with gusto, integrating it into both traditional and contemporary cooking styles. Aaron Franklin, the pitmaster of Franklin Barbecue in Austin, Texas, has extolled the virtues of open-fire cooking. Similarly, Francis Mallmann, the Argentinian fire-cooking maestro, has inspired a global appreciation for the art of grilling with wood and coal, blending Santa Maria techniques with South American asado traditions.
In California, the legendary tri-tip—a triangular cut of beef—is synonymous with Santa Maria-style barbecue. Chefs like Guy Fieri and Michael Chiarello have brought this rustic cooking style to television screens, showcasing recipes that go beyond beef to include chicken, pork, and even vegetables.
The Science of Smoke: Wood and Flavor
The key to any great barbecue lies not just in the meat, but also in the fuel. Santa Maria grills traditionally use red oak, prized for its long burn time and sweet, smoky aroma. But grilling enthusiasts have expanded their repertoire to include mesquite, hickory, and fruitwoods like apple and cherry, each adding unique flavors to the food.
For an added layer of complexity, some cooks adopt Latin American techniques such as tossing whole onions, garlic, or herbs like rosemary into the coals. As these ingredients smolder, they release aromatic compounds that infuse the food with subtle, tantalizing flavors.
Latin American Influences: Gaucho Grills and Asado Traditions
Speaking of Latin America, the Santa Maria grill shares a kinship with Argentinian Gaucho grills, Brazilian churrasco, and Uruguayan parrilla. Each of these grilling traditions celebrates the primal allure of fire and meat, emphasizing simplicity, quality ingredients, and the communal joy of cooking outdoors.
Francis Mallmann’s famed seven-fire method incorporates various setups, including open flames, coals, and iron griddles. Similarly, Mexican barbacoa often involves slow-cooking meat in underground pits lined with maguey leaves, a far cry from the simplicity of the Santa Maria grill but equally captivating in its authenticity.
The Kentucky Connection: Dustin Carter and One Time Fabrication
Enter Dustin Carter, a master craftsman from Kentucky who has taken the Santa Maria grill to new heights. Through his company, One Time Fabrication, Carter blends the rugged charm of traditional Santa Maria and Argentinian Gaucho grills with a touch of Southern flair—and a splash of Kentucky bourbon trail inspiration.
Carter’s designs are a feast for the eyes and the taste buds. Each grill is handcrafted, ensuring unparalleled quality and attention to detail. Drawing on his roots, Carter incorporates bourbon barrel staves into some designs, marrying the smoky essence of bourbon with the open-flame tradition of Santa Maria and Gaucho grilling.
Recipes to Try on Santa Maria and Gaucho Grills
- Santa Maria Tri-Tip: Marinate the tri-tip in a blend of olive oil, garlic, black pepper, and paprika. Grill it over red oak wood until the exterior is crusty and the interior is a perfect medium-rare.
- Grilled Bourbon Chicken: Marinate chicken thighs in a mixture of bourbon, brown sugar, soy sauce, and garlic. Cook over medium heat, basting with the marinade for a sticky, caramelized finish.
- Fire-Roasted Vegetables: Toss bell peppers, zucchini, and mushrooms with olive oil, salt, and rosemary. Grill over applewood for a smoky, herbaceous side dish.
- Argentinian Asado Platter: Combine various cuts of beef, chorizo, and morcilla (blood sausage) for a true South American feast. Serve with chimichurri sauce for a zesty kick.
The Future of Santa Maria and Gaucho Grills with Bourbon Trail Grillworks
The enduring appeal of Santa Maria grills and Argentinian Gaucho grills lies in their versatility, simplicity, and the primal satisfaction of cooking over an open flame. With artisans like Dustin Carter and Bourbon Trail Grillworks at the helm, the tradition continues to evolve, embracing new influences while staying true to its roots.
Whether you’re a backyard barbecue enthusiast or a professional chef, Santa Maria and Gaucho grills invite you to slow down, savor the process, and celebrate the art of cooking with fire. So grab a pair of tongs, stoke the flames, and let the grill do the rest. Because as any seasoned pitmaster will tell you, the secret ingredient is always smoke—and maybe just a splash of bourbon.