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Just pulled the crossmember off mine. The old star nuts inside the tube rusted away and fell apart. I think I will just replace them and bolt it back together.

That would work for sure. I may also just put a brace at 45 degrees in the corners.

What have you all done to tighten up the wobble in a the frame of your old genesis? Everything on my grill is in great condition so I hate to pick up another one on CL just to swap the frame. I tried to tighten the bolt on the lower crossmember but they are rusted and will just break...

You did a great job on that wood! I like the "original" look of the new handle. Have you considered making and selling those? I might need one!