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I replaced the burners a couple years ago and noticed the crossmember rusting then, but definitely wasn't as bad as is in the picture and at the time seemed like the only bad spot on the grill. A couple years later and its seems like the rust really overtook the frame. I've noticed the moisture...

I knew the crossmember was rusted out and I wanted to replace all the hardware with SS. The more I've removed, the more rust I'm seeing.

I am going to attempt to do the crossmember fix this weekend. I will be getting a piece of bar stock and bolting in the new piece. When it comes to painting should I first prime the bar stock and then paint? Is one coat enough or should I do multiple coats? Also other parts of the frame I...

In regards to cut off wheels, are there any particular quality brands you would recommend? It seems like you wouldn't want to cheap out on these.

Thanks guys for all the good info! I'm not sure if I'm totally understanding what it means to stay out of the plane of rotation? If the disc is held vertical are you saying i shouldn't be standing behind in that same vertical line? And I should instead be standing off to the side?

So I'm going to attempt the crossmember rehab this weekend and planning on grabbing an angle grinder. I've never used an angle grinder before...any tips for using one? I know theres some safety issues when using them because they spin like 10,000 to 12,000 rpm. I'd like to get a face shield...

So would something like this work? https://www.mcmaster.com/standard-washers/washers-4/washers-5/high-temperature-plastic-washers-8/ Or go with a stainless steel washer?

For clarification are you saying between the frame and cookbox? So bolthead -> frame -> washer -> cookbox -> nut?

Is this the correct size of bolt for the firebox? It has to go through the frame and firebox right?

I see suggestions to use anti-seize on the bolt going through the frame and firebox. Are there any concerns with anti-seize being exposed to the heat of the firebox? I know the food wouldn't be in contact but I'm just wondering if the anti-seize would smoke inside the firebox and would there...

So even the bolt through the firebox? 316 SS should be fine with being exposed to the heat?

I understand that 316 SS has better corrosion resistance properties but how does 18/8 perform in real-world experiences? I live in Iowa and the summers can get hot and humid and the spring can be pretty wet. Any downsides to using 316?

Those are very nice restores!

Bruce, thanks for the great information! I've watched your video on the crossmember repair and was just starting to think of the supplies/tools I'd need to get and was thinking that it might be an expensive investment since I don't already own this but harbor freight definitely looks pretty...

Hey Bruce, I live in eastern Iowa, in the Davenport Iowa area. We do have a Harbor Freight.

I have a 2005 Genesis Silver A and its been a great grill and I bought it brand new back in 2005/2006. I have the notorious crossmember rusting issue where it meets with the cookbox. There's no salvaging this piece as its rusted completely through and the bolt isn't doing anything anymore...

I often cook chicken breasts on the grill and a pretty good percentage of the time they get overcooked and dry. I bought a thermapen to help me to pull the chicken off the grill when its done and food safe but before its been overcooked and dried out. But my experience so far with taking temps...

Hi Bruce, thanks for the response. I did email Weber just to hear what they say. I figured it would be ok if they're shipping them out this way but just wanted see what others thought. For the frame repair I was looking at doing something like this...

Hello, I have 2005 Weber Genesis Silver A and the burner assembly rusted apart (the crossover tube). I order a replacement and in removing the burner assembly from the cookbox I noticed a hole in the cookbox itself. I have a huge area of corrosion in the bolt that attaches the cookbox to the...