It’s not uncommon to encounter a rusted-out screw hole when restoring an old Weber gas grill. How do you repair a rusted-out screw hole? In some cases, it’s easy enough to clean-out whatever remains of the hole and replace the original screw with a bolt and nut. But in some cases, you’ll want (or need) to repair the screw hole so the original screw can be used again.
Here’s a beautiful restoration of a Weber Genesis 2 by EdW from Silver Spring, MD. He’s documented the process in a series of posts on The Virtual Weber Bulletin Board.
The restoration included a complete disassembly of the grill, repair of the rusted frame, replacements of many internal parts, repainting of the frame/firebox/lid end caps, and some beautiful new woodwork on the work surfaces.
The cooking grates had been recently replaced by the previous owner and the Flavorizer bars were in pretty good shape, but there were plenty of issues with broken bolts and rust on the frame that needed to be addressed.
THyde also replaced the burners, ignition system, and control knobs. And of course, there was lots of cleaning and cosmetic work to be done to make this beauty shine like new again.
TVWBB member KellyMc from Austin, Texas picked up this 1998 Weber Genesis 1100 redhead on Craigslist for just $45.
“I spent about $160 on paint, wood and finishes, warming basket and shelf, catch pan and holder, cover and a propane tank,” says Kelly. “I’ve used it half a dozen times already and it works great. I like it so much better than something new that would have cost twice as much or would have been half as well-made.”
What really stands out about Kelly’s restoration is the woodwork. “I used cedar from Home Depot — 1x2s for the side shelf and just plain fence pickets for the bottom shelf. The handle is the original wood, which seems like very cheap pine, with the gray paint sanded off.
“I sanded everything thoroughly and did 3 or 4 coats of teak oil. Then I sanded again and topped with spray-on spar varnish. I think I did 2 or 3 coats, sanding between each. It looks quite nice and seems plenty water-resistant. I keep it completely covered between uses, so I’m hoping it stays looking great for a long time.”
TVWBB member Mary Teal from Eugene, Oregon rescued this 2001 Weber Genesis Silver C from the back of a trailer headed to the scrap yard. With advice from forum members and a batch of Weber OEM parts, she brought this beauty back to life. She calls it “Ol’ Blue Belle”.
TVWBB member Alejandro DK from West Mansfield, OH picked up this Weber Genesis 1000 redhead for $50 on Craigslist. He invested about $100 in parts and materials plus some elbow grease and ended up with this beauty.
Assuming that you give your grill a thorough cleaning once or twice a year, there’s little you need to do to maintain the inside of your gas grill firebox. Just brush any loose material with a stiff bristle brush or scrape it with a putty knife and you’re good to go. But if you’re restoring an old, abused grill, you might want to do a deep cleaning.
Enter an angle grinder and a cup wire brush. That’s what TVWBB member AnthonyJ used when restoring the Weber Genesis Silver C shown in these photos.
Anthony spent $60 buying this grill and then replaced the following parts during the restoration:
Weber gas grills are notorious for flaking, peeling paint on the firebox. The gas grill warranty covers the paint for two years, which is about how long it takes to start flaking and peeling on your grill! But to be fair, the firebox does get very hot and paint is no match for those high temperatures.
So what to do? You repaint the exterior surface yourself. You do not repaint the interior. The process is pretty straight-forward.
Start by using a wire brush to remove any loose paint. Hit the flaky spots with fine-grit sandpaper to make them ready for painting.
You don’t have to remove the firebox as shown here…this is part of a full-blown restoration. You can simply mask-off the surrounding surfaces with newspaper and masking tape and paint in place.
Use flat black high-temp spray paint to repaint the firebox. Two thin coats of paint is usually better than one thick coat.
Depending on your particular grill, you can even repaint the lid end caps using the same process.
The results are pretty satisfying. A fresh coat of black paint will make your Weber gas grill look good as new. Just remember to save that leftover spray paint…because you’ll be repainting again two years from now.
A popular technique for cleaning exterior porcelain enamel on Weber grills, both gas and charcoal, is to use super-fine 0000 steel wool and a degreasing spray like Simple Green or Formula 409. You can use this technique to occasionally deep-clean your grill or to restore an old grill to like-new condition.
Here are the steps:
Use a damp cloth to remove any surface dirt.
Spray degreaser generously on the surface. Using a circular motion, scrub gently with super-fine 0000 steel wool to remove grease build-up. Apply more degreaser if it begins to evaporate.
Wipe away residue with a damp cloth and check your work. Repeat Step 2 if some areas are still dirty.
Wipe the surface several times with a clean damp cloth and dry with a soft towel to remove streaks.
TVWBB member Rich Dahl made a wonderful grill cart from an old Weber gas grill frame.
“I was looking around for some type of movable service cart for my cooking area and just didn’t find what I wanted, or the price was way out of line,” says Rich. “I was on Craigslist one day and ran across a Weber Silver B gasser for $20.00, pretty beat up, but being in dry Arizona, no rust at all. I bought it, and with a repaint and some surplus clear pine and some trim, I built my own.