Instead of a full restoration this is a quick clean up to restore functionality and aesthetic appeal.
Step 1: Grill
Old busted grill.
Step 2: Photos
Take photos while disassembling.
Step 3: Grill Base
I used a cutting disc on an angle grinder to remove the grill base.
Step 4: Iron
Remove the rust from the grill top with a wire brush and an angle grinder cup brush.
Step 5: Grease Catch
Remove the old grease catch and replace with steal sheet metal.
Step 6: Legs
Wash, sand and paint the legs.
Step 7: Body
Remove rust with rust remover and a wire brush. Sand smooth and coat with high heat grill paint. I didn't paint the inside of the grill hood.
Step 8: Burners
The bolts on the burner base had broken off. I drilled out the bolt and tapped the hole. I then cold welded in new bolts.
Step 9: Hardware
Soak the hardware in vinegar and brush clean.
Step 10: Reattach
Reattach all the hardware and replace bolts where necessary.
Step 11: Burner Cover
I cut the welds on old rusted grill grates and mounted new expanded sheet metal.
Step 12: Base
Create a base for the grill and propane tank to sit on.
Step 13: Paint
Paint the base.
Step 14: Assemble
Step 15: Season
Turn on the burners and heat up the grill for a half hour to burn off any volatiles. Season the inside of the grill.
Step 16: Grill or Stove
Because there are 60,000 btu burners the top grill can be removed. The burners can be used for stir frying with a wok or cooking in a stock pot.