Replacement Carryover Tube for Gas Grill

A carryover tube brings the gas flame from the burner with the igniter to the other burner on a gas barbecue grill. After five years of occasional use, our carryover tube was no longer usable due to rusting away. I made a replacement tube from 18 gauge steel with a welded construction. I wanted to see if I could also use a metal tube, like 1/2 inch EMT, that is, electrical conduit to make a good carryover tube without any welding. That is the purpose of this Instructable.

A replacement factory carryover tube is not expensive. But, making your own satisfies one’s desire to be independent and make what you need, removes any need to wait for an order to be delivered, and provides a carryover tube that will last much longer than the very thin original.

Supplies

• Steel tube like electrical conduit

Step 1: Mark for Length

The photo shows my welded carryover tube and a piece of EMT. I marked the EMT for length so I can cut it.

Note: EMT has a zinc coating. I need to remove as much of it as possible to keep fumes from coming into contact with food. A flap disc on a grinder is one method. Another is to soak in muriatic acid or vinegar to remove the zinc coating. In the past I have tried burning off a zinc coating in preparation for welding, but it was not very successful.

Step 2: Partially Crush the Tube

After cutting the tube to length, use a big hammer to partially crush the tube so it has a somewhat flattened oval shape.

Step 3: Slit the Tube

Put the partially flattened tube in a vise and slit it lengthwise. Position the cut as shown in the photo.

Step 4: Form the Tube

Put the slitted tube into a vise and force part of the tube inward so there is an overhang. See the drawing in the second image. Note the gap and the overhang.

When I made the welded carryover tube I did not notice the gap and the overhang because the original carryover tube was so badly rusted away. Gas in the burner without the igniter did not ignite and burn. It was a puzzle to me until I found an image of a replacement carryover tube.

The exact shape of the tube, oval or square corners, is not critical as long as the gap and the overhang are present.

Step 5: Mark

Place the tube upside down on the burners and mark the inner edges of the burner tubes.

Step 6: Prepare the Ends of the Tube

Remove the bottom half of the tube at the ends so the tube can fit down between the burner tubes.

Step 7: Flatten and Align the Ends

Flatten the ends of the carryover tube in a vise. Use an adjustable wrench to make certain the ends do not have a twist that puts them at different angles. They should lie flat on the burner tubes.

Step 8: Fit the Ends to the Burner Tubes

Use a pair of pliers to bend the flattened ends of the tube as shown. See the second photo. Bend the flat raised ends of the tube around a rod or tube about the same diameter as the burner tubes.

Step 9: Check the Gap

Use a screwdriver to make certain the gap is present along the length of the tube.

Step 10: Secure the Tube in Place

Fit the carryover tube to the burner tubes. Mark the center of the posts on the burner tubes that will hold the carryover tube in place. Use a center punch so holes drilled will be precisely located. Drill to 5/16 inch.

Step 11: The Moment of Truth

Install the locking pins through the posts. If needed, use a pair of pliers to pull the carryover tube to the burner tubes so the locking pins can be put into place. There may be burrs from drilling, etc. File these away for a good fit.

Turn gas to the igniter burner on full. Press the igniter button. On this grill the igniter is attached to the right burner tube. When the tube with the igniter is burning, turn gas on to the other burner tube. It should also ignite in a second or two.