Genesis Platinum Series II Restoration started


 
The time has come to start the restoration of my 1996 Genesis Platinum Series II. I have my 4900 to keep me cooking so I have plenty of time to finish the job.
It started life as this:

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In about 40 minutes I had it down to this-

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It came apart pretty easily as the Oversized Summit series frame used on the Platinum II is a much nicer setup than the Genesis frame with the interior bolt holder that always seem to turn to rust powder as the years progress. The Summit frame has welded tabs to the square stock that are threaded for 1/4" 20 bolts.

The only rust issue on the entire grill was the left side frame support that connect to the firebox:

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I ordered the replacement with several other items ereplacementparts.com as I wanted to see exactly what shade of black Weber used for the Frame.
I am super anal about these things so working in an Auto parts store I had access to many paints to chose from and I purchased several and painted the smaller pieces to compare them to the factory support brace color. The Frame colors are on the left of the pic.
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The frame is in great condition so I sanded down some light surface rust by the weld joints, shot it with VHT Rust Convertor, sanded with 320 grit, then hit the spots with Etching Primer, lighted sanded with 400 grit, and then used Wax and Grease remover to cleanup. If it ever stop raining here in Mass I will apply several light coats of black paint to the frame.

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To be continued...
Hi Jeff, I just came across your post while doing a search. I am in the process of restoring my 2004 Natural gas Genesis Gold C. How did you do the repair on the rusted frame rail on the left side of the cook box. Mine is in similar condition. Mine is not removable, it would have to be cut out and re-welded.is that what you did? Secondly, Weber did replace my lid and cook box under warrantee (21 years old, impressive on Weber’s part) but I don’t know what size bolt to use to attach the left frame rail to the cook box. Help please nd thanks.
 
Brian, you can weld in a new piece or do this:

Also, you want a 1/4" stainless bolt for the cook box that is 2" long.

1/4-20 x 2​


 
Oh, and used this style of "Star nut" connecting nuts for the tube. Not the ones in the "how to".


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