2002 Genesis Gold C Build

[Bruce]

Yah, I have used a couple dozen sets of them on my rehabs. Only 2 or 3 of them posed a problem like yours. It took me a while to figure out it was just a flaw in the tubes and not some other issue. I guess I should compare lengths of them and factory weber burners. My guess is they will be an 1/8" or so shorter.

 

[Cody Bratton]

Yah, I have used a couple dozen sets of them on my rehabs. Only 2 or 3 of them posed a problem like yours. It took me a while to figure out it was just a flaw in the tubes and not some other issue. I guess I should compare lengths of them and factory weber burners. My guess is they will be an 1/8" or so shorter.

That’s where my fear kicked in. I had tagged everything for this one. Aside from the manifold The one I did for it originally must’ve grown legs. Because all of my stashes seem to not have it. I was looking at the pics, I posted earlier and it’s there

After putting the knob’s on there’s one valve that is moving freely, but the stem seems a bit loose. So I’m guessing I’ll end up taking it all back apart to reassess

 

[Bruce]

If you are having problems with the middle burner. You can always just position the burner and spot weld the middle burner to the crossover tube to keep it from moving left and right too much.

 

[Cody Bratton]

If you are having problems with the middle burner. You can always just position the burner and spot weld the middle burner to the crossover tube to keep it from moving left and right too much.

That thought has crossed my mind since yesterday. Thought about just dropping a tack weld on the ends of the tubes where they are notched as well, to get a little bit of bite out of the screws to keep them more stationary over grinding material on the cookbox tab.

In addition to swapping out the valve. I have a couple sets I have done already. The stem in the one valve is just loose and has a fair amount of play once the knob is on. Wasn't as noticeable just exercising the valve in my hand. I guess I will have a couple spares now

 

[Cody Bratton]

I guess this thing is cursed! Are frame extensions different sizes? Or are the holes different on different years? This was a 2002 and I’m using the plastic ends off of a 2003 silver B with dual folding tables. And the hole for the bolt is like a 1/4” off.

The original end pieces off this grill are pretty rough and I thought they were interchangeable. I still have the original ones that are totally in love with the frame extension.

 

[Samuel]

I have never encountered that with the trim ends I have that I can remember. The only difference I have found in them is that sometimes bolt hole is in the front on right side and other times bolt hole is on inside of the front frame end.

 

[Cody Bratton]

Well this really blows. I figured since I only had a little time tonight to work on it I would get some small stuff out of the way. Oh well, just another road block. I will have to go thru my parts at home before I move along.

What I can tell you, is that this is super defeating. I have black ends, maybe I’ll go full blackout on it. I can tell you I’m heading home to mix a cocktail.

 

[Samuel]

If you decide to go black out ends does that mean you will change the handle too?

 

[Cody Bratton]

The only black handle I have is for what I call the curve lid, which has the center mounted thermometer and bezel. I have a few of those lids that are in nice shape.

I did also set into place the SS cookbox cover, and I’ll very likely be painting that black (not the one that came on it though, as it’s in great shape. I have a rough looking one that I think will clean up and look good in black.

 

[Cody Bratton]

I also recall a few of the more tenured folks on here giving their insight and guidance into the crazy things I wanted to try, so if you’re one of them, now is your chance to say I told you so!

On a side note, the valve change went flawlessly, and I marked a couple spots to put some tack welds to help hold the burners more firmly into position. Here’s a pic of what the center burner looked like after rolling it around.

I also assembled a whitewall. I forgot to take pics before I snapped it in (I only did one, because I want to see how it turns out). But I carefully dabbed small amounts of black RTV onto the backside of the whitewall on the small raised circles I didn’t know about around the Weber cutouts. I found that a plastic Folgers can that I use to keep bolts in fits perfectly to apply heavy and even pressure all the way around the whitewall.

 

[Cody Bratton]

Well I am thrilled with how well the wheel worked out! The Weber area was flopping out probably close to 1/4” on each side. So I’ll call this a victory. And the small dabs worked wonders as to not squirt out into the letters.

I opted for the white center cap because I think the wheels are kinda cool and needed a little more flare!

 

[Cody Bratton]

So after pounding with a SS rod thru the frame extension, the two fell out of love, and when it finally came out it shot a few feet to the floor, and then an small piece went flying in a different direction.

Good news is I guess I saved a frame extension

 

[Bruce]

I have spent a lot of time trying to get those end handles out of the frame on several grills. Heat, penatraing oils, and pounding several different ways to include like you did. I am always amazed at just how "STUCK" those things can get. I have had to actually cut the frame part off the handle to save the handles.

 

[Cody Bratton]

Back in October they wouldn’t budge. Even after a week long soak in penetrating oil. I tossed them under the bench thinking maybe I’ll try again someday. It only took maybe a dozen good hits. Maybe time is your friend on the soaking. Just for kicks I tried the other one. Popped right out, and survived the floor collision. Maybe only because I have several of those style in good shape.

I guess I have my plastic painting lab rat though.

 

[Bruce]

I have done the same thing. Weeks between tries after soaking. Heating until the dang plastic inside started melting and then trying to pound it out with a rod and 2lb maul. Probably 2 hours or so of working on it that way before I finally grabbed the angle grinder and a cut off wheel. I have broken several of them trying to get them out over the years.

 

[Cody Bratton]

I didn’t like the thought of not having them off and putting them onto another grill. Just wouldn’t feel right. I’ve got 3 golds to make into one, but this setback has been mind bending.

I’m not giving up, but it’s really taken the wind out of the sails, that took a while to find.

 

[Cody Bratton]

Went deep into my stash, apparently I forgot about a bin of tables and such that I have at work! I found an end handle that works, and while it’s dirty it looks promising. Going to get a soaking in bleach tonight and see how it fares.

 

[Samuel]

Awesome Cody I hope you are successful. Nothing can halt a project more then a missing part.

 

[Cody Bratton]

And just so you guys can see, that I’m not crazy. Top piece is the one I wanted to use. Bottom piece is my newly found piece.

 

[Cody Bratton]

And this project is right back on track!