Genesis 1000 Bottom Crossbar Repair
- Thread starter DannyGarcia
- Start date
Steve Hoch
TVWBB Platinum Member
Do you put a bolt in them and pound them in like your driving a nail? It really is that easy to do.
DannyGarcia
TVWBB Super Fan
Well I took 3 crossbars to the blaster. Two that were not broken and 1 that was broken on 1 side. So, I should be good ...
Steve Hoch
TVWBB Platinum Member
Interesting, they never just push into the tube for me. I have to tap them in with a hammer.
Steve Hoch
TVWBB Platinum Member
Ok, yeah. That's exactly how I do it too.
John-NY
TVWBB Super Fan
I’m soooo glad you said this and I read this before I start my repair. Talk about tricks of the trade
Steve Hoch
TVWBB Platinum Member
Just make sure you don't put the connector down too far or the bolt won't be able to make it in. I learned that one the hard way.
Steve Hoch
TVWBB Platinum Member
I had more connectors, so I just put another one in front of the one I sunk.
Steve Hoch
TVWBB Platinum Member
The only drawback to doing that is that the frame can't easily be taken apart again if need be. That being said, I wish you were my neighbor, it would save me a lot of hassle on some of the crap that I deal with on my grills.
Mark-Anaheim
TVWBB Member
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.
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.
John-NY
TVWBB Super Fan
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?
TomRc
TVWBB Pro
I use a 5/8” long bolt and thread it all the way into the insert just finger tight. I then turn the tube upside down on a solid flat surface and hit the other end with a rubber mallet. Then I just back out the bolt by hand. It sinks the insert evenly and to a perfect depth every time.