Genesis Silver B?


 
Samuel said:
B

Thread 'One way to get the plastic end caps out Silver'

So after my disaster with the paint on the Silver C plastic end caps had another set from a B. After reading all the horror shows of people breaking them when they tried to get them out and I had one that would not budge and I needed it. So I had soaked them down for days one would not budge and yes I pushed the clips had someone hold those in with a screwdriver. So I had some 1/2 copper long enough to insert in one end to small diameter I know but my goal was to get them out maybe 1/4 inch soak again with PB Blaster which I did last night.

I knew I needed something thicker so I went...
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His frame is different and he has the handle extensions which will not allow you to insert a dowel all the way through the frame. He can get about a 1/2" dowel down through the extension though.
 
I have also found that sometimes where the nut fitting into the plastic handle, bulges out, so putting the screw back in a few threads and gently tapping that bolt in pushes the nut in and allows a little extra movement. I have also carefully heated the metal near the handle with a smaller butane torch, softens the plastic enough to give a little more room, without totally wrecking the handle.
 
You're fighting 2 forces. Corrosion of the internal frame plus the slight swelling (not really swelling but I don't know what else to call it) that occurs to the plastic itself. Eventually they want to weld themselves together. Plenty of penetrating oil but also try some heat (not a torch) but a heat gun on low or maybe a hair dryer. A little warmth in there would likely help things out
 
Larry, I tried all those things on my last one. I tried pounding it out with a wood dowl and 2 lb hammer. I soaked it over about a week with PB blaster. I tried a propane torch at various stages of heat. I got to the point that smoke from the burning PB Blaster and plastic were billowing out the extension and still it would not budge with the dowel and hammer. It never budged a MM. I wound up cutting the extension off of it.

I have come up against several over the years that just are not going to come out without getting destructive. In those cases, I decide if I need the extension more than the handle. If I need the extension. I just break the handle off, use a big drill bit to drill down the middle of the handle flange and then use a sawzall to cut up the rest of the handle flange until I can get it out. It amazes me how stubborn the handles can be bonded into the frames. I actually bent the frame on my last attempt and had to do some rewelding to fix it.

It is one of those things where I wish someone had a secret trick to share for those really bad ones. I have tried everything I can think off and some just won't cooperate.
 
Here is the setup that ultimately worked the best for me. I was able to pound them into submission. The weld did crack on one of the extensions but I don’t see why I won’t be able to tack it back on with the welder. (The torch on the floor was out from another project. I didn’t use it on the frame.)
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Yes, any time you pull from the extension in that manner the weld will give. Same thing happens if you were to leave it assemble on the grill and pound the end cap out with to much force. At least that is what I have found also.

Happy to see that you got them out. Now that you have them out what plans do you have?
 
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Samuel said:
Yes, any time you pull from the extension in that manner the weld will give. Same thing happens if you were to leave it assemble on the grill and pound the end cap out with to much force. At least that is what I have found also.

Happy to see that you got them out. Now that you have them out what plans do you have?
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I’m most likely going to sand down what and rust spots to bare metal, try to repaint everything, replace parts as needed to get her up and running.
 
SStratton. Another option with those brackets on the shelf extensions is to simply just weld them permanently together. That would be a viable solution to the broken bracket if you don't see a need to take the frame apart ever again.
 
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