Genesis Restoration Cookbox Damage

[Derek-IL]

Besides aesthetics and durability concerns, are there any major operational or safety concerns with having these holes here? It seems the sandblasting removed any weak brittle metal that was remaining so what’s left feels pretty structurally sound. There is a large hole at the front wall of the cookbox at approximately the same height as the burner hole (I think for match lighting?) so I can’t imagine it’s a fire hazard or airflow issue with normal operating use?

Newbie here, but if it makes you feel any better, I’m in the same boat. This was a spur of the moment project idea for me. Got the inside cleaned out with some oven cleaner and noticed holes where the flavorizer bars sit. About 4-5 holes in total, most of them tiny with the biggest one about the size of a pencil.

I’m just gonna roll with it, especially since I already spent money on parts. I’ll still have a cheaper and better grill than a $200 one from Walmart.

Report back if you try any JB Weld, I plan on doing the same when I get around to working on it!

 

[LMichaels]

Honestly if me? I would not use it. And I would not "justify" "well there is an ignitor hole", and yes that is true but THAT hole was engineered to be there. Unlike your hole(s) in the sides of the cook boxes. Me? I would either A, fine a SAFE way to patch or B look for a different fire box. After seeing how hot things got under the control panel of my old Summit (now Jon's Summit), I'm of a mind toward safety first. These are not aesthetic issues IMO

 

[Scott R Springer]

Honestly if me? I would not use it. And I would not "justify" "well there is an ignitor hole", and yes that is true but THAT hole was engineered to be there. Unlike your hole(s) in the sides of the cook boxes. Me? I would either A, fine a SAFE way to patch or B look for a different fire box. After seeing how hot things got under the control panel of my old Summit (now Jon's Summit), I'm of a mind toward safety first. These are not aesthetic issues IMO

Unfortunately haven’t been able to find a donor grill anywhere near me. Sounds like people have spoils in other parts of the country . I think I’m going to try a mesh + JB Weld repair and see how it goes just to close off any potentially hazardous airflow.

 

[LMichaels]

Unfortunately haven’t been able to find a donor grill anywhere near me. Sounds like people have spoils in other parts of the country . I think I’m going to try a mesh + JB Weld repair and see how it goes just to close off any potentially hazardous airflow.

Unless it was a VERY VERY small hole I would not do this. But hey, you do you I'll do me. I ALWAYS err on the side of safety and IMO that ain't it. Best of luck. I truly hope it works and nothing bad happens

 

[Bruce]

Newbie here, but if it makes you feel any better, I’m in the same boat. This was a spur of the moment project idea for me. Got the inside cleaned out with some oven cleaner and noticed holes where the flavorizer bars sit. About 4-5 holes in total, most of them tiny with the biggest one about the size of a pencil.

I’m just gonna roll with it, especially since I already spent money on parts. I’ll still have a cheaper and better grill than a $200 one from Walmart.

Report back if you try any JB Weld, I plan on doing the same when I get around to working on it!

JB weld works great on those kind of holes. I actually used it on holes where the flavo bars sit on my first keeper rehab. My son has that grill now.

 

[LMichaels]

JB weld works great on those kind of holes. I actually used it on holes where the flavo bars sit on my first keeper rehab. My son has that grill now.

On a small hole I'd have no issue giving it a whirl. But the holes in the photo(s) appear large enough to drive a truck through. If (and I MEAN IF) I were to recommend trying it I'd want it backed up with a metal patch similar to what Jon did with his old Summit cook box. But, I would not simply slather in glorified "Bondo" and then put the coals to it. Again, I've got a whole different level of what I believe are acceptable "risks" than many. But, also I figure I didn't get to be this old by not analyzing potential risks