I got my grill for free from my dad, he was getting rid of it and I needed one. I've had it for several years and it works well - at least it did, until recently when the burners started rusting out. I ordered some replacement burners from Amazon along with some heat plates and new enamel coated grill grates. By the time I was done I expected it to be as good as new.
But, when I started removing the burners I discovered that the metal ledges that the burners normally sit on were rusted so badly that they crumbled like an ancient scroll when I removed the old burners. The main grill body is not sold as a replacement part, thus my only path became clear - I was off to the hardware store.
Step 1: Materials
Note: All the hardware below is in 304 stainless steel because I don't trust galvanized to last very long under the high heat outdoor conditions.
To create a "shelf" for each of the three burners I used the following items,
- Anti corrosion Spray paint
- 3x 1/4" U-bolts (My local Lowe's store sold some that with a plate-type washer and two nuts)
- 6x additional 1/4" stainless nuts (including those that came with the U-bolts that makes 12x total)
- 18x split-lock washers
- 12x 1/4" flat washers
- 3x 1/4" wing nuts
- 6x 2" fender washers
- 3x 1/4" by 1" bolts
- Electric Drill
- 5/8" sheet metal drill bit
- a wrench that fit the nuts
Step 2: Measure and Drill
Two of the three burner ledges on my grill fell off when I tried to remove the burners, the remaining ledge gave me an idea of how high to place my replacement ledge. I used a pencil to mark the locations for the holes.
Next I drilled two holes for each new shelf/bracket.
After drilling the holes, I applied some high temperature anti-rust spray-paint to avoid future corrosion to each area where I had removed paint during the drilling process.
Step 3: Install the Brackets
This was the easiest part, especially since the holes were a bit bigger than the bolts, which gave me a little room for error.
For each the U-bolts:
- Place a nut on each side of the U-bolt and spin it till it reaches the top of the threads
- slide a split-lock washer up to the nut on each side
- slide a flat washer on each side until it touches the split-lock washer
- insert each assembly through the holes you've drilled in the back of the grill
- place the plate washer over both sides of the bolt
- slide another split-lock washer up to the plate washer on both sides of the bolt
- place another nut on each side of the U-bolt
- Tighten the inside nuts with a wrench
Step 4: Install the Burners
After installing the brackets I used a 1" bolt, several different types of washers and a wing nut to attach each of the burners to the bracket assembly.
For each bolt:
- Slide on a split-lock washer
- Slide on a flat washer
- Slide on two fender washers
- slide on the burner
- loosely attach a wing nut
After assembling each set of burner hardware I placed the large fender washers on the top and bottom of the previously installed bracket and tightened the wing nut by hand while holding the bolt still with a wrench. The fender washers should sandwiched around the u-bolt assembly and hold the burner in place.
I repeated the procedure for each of the remaining burners and everything came out very clean, and the stainless hardware will probably outlast the rest of the grill.