Genesis 1000 Frame Repairs

[Rich Dahl]

Derek,
I have the exact same grill that I bought new in 1998. Finding a doner grill with a good frame may be the quickest way to go. Although there was nothing wrong with my frame about four years ago, I found a Gen 3000 and converted mine to a 2000 (Took off the side burner and put in a shelf instead.)

 

[RobWorthington]

Derek, it didn't take long, but you are already showing clear signs of "Weberitis". As symptoms progress, you will find several Weber grills in various states of condition showing up in your drive way. You will find tools and supplies for working on them start to appear in your garage. Eventually you will have multiple grills for personal use and possibly be selling others that you have rehabbed.

This is a real thing. My wife is getting nervous as she sees me pulling apart my other newer Genesis after my resto is almost done. It’s like she can sense the itis taking hold. Lmao

 

[Richard in NS]

I patched one up by pop riveting a piece of pipe strapping on it and it got me through from fall until spring when the weather warmed up but like Bruce said, I wouldn’t wait too long.

 

[Scott Smith]

I have never taken apart this frame, so I may be out to lunch with this idea. My thought was that it may be possible to rotate the rusted area next to the firebox (even after it is repaired) to another, less conspicuous location such as the inside or bottom so that the most viewable side of the grill appears as original as possible.

 

[Bruce]

That crossmember is welded in. You could cut it out and rotate it and then mount it back in, but you would be far better off cutting a 1 1/4" piece out of another Weber grill or buying a new piece of 1 1/4" square stock at a big box store and fabbing that in.

Check this out: https://tvwbb.com/threads/how-to-weber-frame-cross-member-repair.77334/

 

[Richard in NS]

Bruce’s method in the video worked for me.

 

[LMichaels]

Wish I knew how to weld

 

[Bruce]

Once you get the basics down. It is just practice

 

[LMichaels]

Believe me I tried so hard to learn. Just one of those things for me

 

[DanHoo]

Once you get the basics down. It is just practice

I've learned it helps to have a welder too. I used to co-own one but it moved too far away.

 

[Andrew F]

Wish I knew how to weld

Wire feed, flux core mig is pretty easy. The hard part is getting the settings correct. Add shielding gas and it starts to look like you know what you are doing. I suggest you take a class ( most trade schools offer a one day “into” class ). That will get you well on your way.

 

[Gary - bassguitarist1985]

I have a 90A Chicago Electric flux core i modded with a 100A bridge rectifier and large electric cap so i have true DC welding. It takes practice to get a good technique.

Rebuilding a Weber 900 series. I did do the captive nut fix on the lowr cross tube however.

 

[Steve Hoch]

I have a 90A Chicago Electric flux core i modded with a 100A bridge rectifier and large electric cap so i have true DC welding. It takes practice to get a good technique.

Rebuilding a Weber 900 series. I did do the captive nut fix on the lowr cross tube however.



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Nice job! There really isn't any reason to weld those bottom crossmembers in anyway.

 

[Gary - bassguitarist1985]

Nice job! There really isn't any reason to weld those bottom crossmembers in anyway.

Thank you! Yeah it came out great! Im no pro, but I'd say I'm capable.