Help with Genesis 1000 Frame

JStone GA

New member
Hi Guys-
I'm trying to get started restoring my Genesis 1000 from the 90's and I need a little advice on the frame. I've read thru the stickys and watched the video on replacing the crossbar. I feel confident I can complete the rehab but need advice about the frame because I will have to do more than just replace that crossbar- I have rust on the side crossbar and then also the front and back where the nut is and then also as you will see in the attached pictures - one of the legs where the caster goes is busted...
Where to start?
I'm not sure how to take the frame apart to repair it and is it even repairable?
Should I take it to a weld/fab shop?
https://imgur.com/7Gagsre
https://imgur.com/6ajhCv2
https://imgur.com/vWwcOf8
https://imgur.com/H6LbEIW
https://imgur.com/X1LL3mN
https://imgur.com/R46Vudr
 

Stefan H

TVWBB Wizard
I personally would use this as parts grill and try to find another 1000-5000 with a better frame. Yes a welding shop can probably build a frame but it will be expensive.
 

JStone GA

New member
Thx for the input- I'm kinda sentimental about this one since I've had it a really long time. I'll see if my buddy who welds can help me out and I'll let y'all know how it goes...
 

Stefan H

TVWBB Wizard
If you are getting a frame welded you might want to go with SS. This way you will get a "forever" grill.
 

Jon Tofte

TVWBB Honor Circle
SS sounds expensive! I'm hoping to do this somewhat affordably.
I would think the welding is what will cost, but here are some on Amazon you can compare to regular steel:

1 INCH
https://www.amazon.com/exec/obidos/ASIN/B003TPFK8U/tvwb-20

1.5 INCH
https://www.amazon.com/exec/obidos/ASIN/B003TPLI72/tvwb-20

The thing is that using this will make your frame almost invincible. When you add having the aluminum firebox and porcelain coated hood, you are really down to just replacing consumables like the burners and flavorizer bars.
 

Bruce

TVWBB Olympian
I agree that the best course of action would be to find another donor grill and steal the frame from that one. But, if you really want to repair the current frame, I would not go with SS as others suggested. Here is why. If you just replace certain parts with stainless, it isn't going to be a "Forever grill" because you still will have plenty of regular steel in the frame. If you recreate an entire frame out of stainless, it would be EXTREMELY costly for both parts and labor and you probably would not be able to construct it within specs enough so that everything fit correctly. Some parts of the frame are formed metal and not just square bar stock.

Those 1000 grills are pretty common to find for free to $50 and you will have a good chance to find one with a healthy frame. I would go that route, otherwise, if you are set on patching up the original frame, I suggest regular steel square stock.
 

JStone GA

New member
Thanks for the links! I will get started with a comparison. I have a friend that will do the welding so cost on that isn't an issue.
 

JStone GA

New member
Thanks Bruce - I just saw your reply. That makes sense! I'm going to try and salvage it and then if that doesn't work I'll see what I can find.
 

Jon Tofte

TVWBB Honor Circle
Yeah, I guess I was thinking along the lines of replacing almost all of the frame, not that I ever tried. I have, however, replaced the leg bottoms and the horizontal bar that the firebox connects to with stainless. While I agree with Bruce that this only a selective cure, it does eliminate the two biggest problem areas. The one you are starting with is even further gone. Getting a donor might be the best plan.
 

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