Genesis 1 Restoration: Reassembly

[Kurt Donnelly]

At long last, the parts are prepped and the reassembly begins.

 

[Bruce]

Just box up all the parts you can't figure out where they go and send them to me.

 

[MarkCuda]

Is that 8001 bran new in the box ?

 

[Timothy F. Lewis]

Just box up all the parts you can't figure out where they go and send them to me.

You are just so helpful Bruce!
What a great guy, if you can’t figure something out, post pictures and one of the giants of restoration will walk you through it!

 

[Rich Dahl]

At long last, the parts are prepped and the reassembly begins.

Looking forward to this Timothy, got my 85 gen 2 waiting for some cooler garage temps to get started,

 

[Kurt Donnelly]

So as I put the new burner tubes in, I noticed they were previously held in place with with a machine screw or such. I'm considering just drilling a hole straight through the flange and aluminum and putting in a sheet metal screw to hold it in place. I'm also considering to not even bother, since it obviously went a long time unsecured with no issues. What do you guys think? Is it worth any more effort or just let it lay there as is?

 

[Bruce]

I highly suggest you create some form of keeping them in place. Just bouncing your grill over a rough surface would likely have them fall off the mounts and then you are looking at serious fire issues.

 

[DannyG]

So as I put the new burner tubes in, I noticed they were previously held in place with with a machine screw or such. I'm considering just drilling a hole straight through the flange and aluminum and putting in a sheet metal screw to hold it in place. I'm also considering to not even bother, since it obviously went a long time unsecured with no issues. What do you guys think? Is it worth any more effort or just let it lay there as is?

The grease will hold it !

 

[Bruce]

Judging from some of the grill I have picked up, I don't doubt that a bit.

 

[Kurt Donnelly]

I highly suggest you create some form of keeping them in place. Just bouncing your grill over a rough surface would likely have them fall off the mounts and then you are looking at serious fire issues.

Thanks for the suggestion Bruce.
I have an 11/64" cobalt bit and 3/16" stainless sheet metal screws. Figuring / hoping that difference will give the screws just enough bite into the firebox, without being so aggressive as to break anything. Also figuring, even if it's not enough of a bite, the screws will act as pins to hold the tubes in place. Will post the results.

 

[DannyG]

Thanks for the suggestion Bruce.
I have an 11/64" cobalt bit and 3/16" stainless sheet metal screws. Figuring / hoping that difference will give the screws just enough bite into the firebox, without being so aggressive as to break anything. Also figuring, even if it's not enough of a bite, the screws will act as pins to hold the tubes in place. Will post the results.

Why not try and drill in the same spot at where the bolts broke off

 

[Mark-Anaheim]

i would center punch the old screw so drill will not wander. Start small 1/8” bit with a drop of oil or 2 as you drill.

Then you can go larger on bit for screw. Often the old bolt or screw will crumble as you get close to screw size.

 

[Kurt Donnelly]

Why not try and drill in the same spot at where the bolts broke off

Convex remains are convex. And harder than aluminum.
The end result seems acceptable. Removal may be tricky, but I'll worry about that in 10 years or so.

 

[DannyG]

Convex remains are convex. And harder than aluminum.
The end result seems acceptable. Removal may be tricky, but I'll worry about that in 10 years or so.

View attachment 96363View attachment 96364

Looks good. If you clean those up every season, you wont have an issue.

Or get a bit of a longer screw and cut off the head. Use it like a post so you can lift them up and off.

 

[Kurt Donnelly]

i would center punch the old screw so drill will not wander. Start small 1/8” bit with a drop of oil or 2 as you drill.

Then you can go larger on bit for screw. Often the old bolt or screw will crumble as you get close to screw size.

I took that approach for the manifold bolts; shaved them level then used a small bit to make a pilot hole. Went pretty easy.
Took the alternate approach here, seemed to work out. Removal may become its own issue.

 

[Steve Hoch]

That works.

 

[LMichaels]

Use those centering bits me and Bruce use and speak about, trust me here you will thank me

 

[Kurt Donnelly]

Use those centering bits me and Bruce use and speak about, trust me here you will thank me

You mean the ones in the same aisle as the left handed monkey wrenches?

 

[Kurt Donnelly]

The grease tray seems to be unavailable for the Genesis 1. I patched up the holes with sheet metal and JB Weld High-heat epoxy.

Might not hold up, will rivet if it looks sketchy after grilling season. Would still like to replace it if I ever find one in the wild.

 

[Bruce]

Nice temp fix. but it will continue to rot away. These trays have not been produced by Weber for a long time and even the aftermarket outlets have stopped making them many years ago. They are becoming harder and harder to find in any kind of decent shape in the wild as well.

Good luck finding a replacement. You will eventually score one.