Genesis 1000 Bottom Crossbar Repair


 
John-NY said:
So does this jig basically just pressure push the fitting into the square opening, then you unscrew the bolt and the fitting remains inside?

And the nut is basically setting the depth?
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Yes sets the depth but most importantly keeps it 90 degrees to end so threads are parallel for bolt
 
Mark Has a good point. If you don't get the fitting square inside the tube, you stand a real chance of cross threading it....Been there, done that, and it isn't fun.
 
As ex machinist all about pressing a pin, or fitting into hole or tubing 90deg and to consistent depth.

The fender washer is 1 1/4” dia so it hits all edges of 1” cross member when you tap down on bolt head. The hex nut with single washer was perfect.

The 1st one I did not have washer and the star blade was too close to end of tube. Concern with it pulling out when used, added washer to seat about 1/16” deeper.

Yes no cross threading or just binding when bolting in frame.
 
Guys aren't these inserts going to make the crossbars about 1/8 too long once added to both sides ? The dont sink inside the bar ...
 

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You should use the star inserts I linked earlier in this post. Those will pull the flange tight to cross member but never force the internal teeth to bite and hold cross member in place.

Weber used the internal star for mechanical connection.

When I tightened the bolt the star bulged the outside of the tube in 4 points and crossmember rock solid, that can’t happen with those caster inserts. They hold stem casters in furniture from unthreading and rely on gravity to stay in place not sideways install
 
Mark-Anaheim said:
I just installed (4) of these star nuts in the cross braces last week


Star inserts like these go inside and wedge against the tube like the OEM. Some people linked the McMaster Carr with the square plate, those are for leg ends to install casters when the frame weight pushes down on the plate and the star inside attempts to keep it from turning vs pulling out like in our application.

I used a 1x4 piece of wood, drilled a 1/4" hole, and put a 1 1/2" 1/4-20 bolt through. Used a fender washer on both sides. Turns out the fender washer is bigger than the 1" tube so when you tap the bolt head down on top of the board the bottom washer drives insert into the tube square to end.

I added a 1/4" washer below the nut, so the insert would go just a little deeper into the tube. When I installed and tightened up the 1/4x3-2" frame bolt I could see the star washer making a small bulge visible on the tube OD, so know it was making a good bite into the inside. Rock solid, very happy with this repair.

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Yea Ill order these I guess
 
I suggest you do Danny. Grinding the silver part on the square ones will likely expose that metal to rust and it could turn into a mess quickly.
 
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