New Addition to the Family, rehab advice appreciated - Weber Genesis E-310

[Kyle in Woodstock]

Use a blowtorch. I had a similar issue. I even drilled through the bolts without touching the aluminum fire box and they still would not budge. I hit it with a blow torch for a few seconds and it dropped right out on its own.

I have one of those small blow torch attachments that fits on those mini propane tanks, if that what you are talking about? Just heat it up a little?

 

[Kyle in Woodstock]

Kyle, be VERY VERY cautious about using a punch on the fire box. Cast aluminum becomes very brittle with age and heat. It will shatter like glass. Ask me how I know........................go ahead

Did you shatter a fire box?! Man I bet you were so ****ed... That would be the worst

 

[Bruce]

I have one of those small blow torch attachments that fits on those mini propane tanks, if that what you are talking about? Just heat it up a little?

Yep, the kind that fits on a 1lb propane bottle should work just fine

 

[LMichaels]

Did you shatter a fire box?! Man I bet you were so ****ed... That would be the worst

Yep, I sure did and I sure was.

 

[J Grotz]

I have one of those small blow torch attachments that fits on those mini propane tanks, if that what you are talking about? Just heat it up a little?

That's just what I have from Harbor Freight. I think I heated it for 15-30 seconds, though it may have been a little longer.

Here's what I was faced with:

I applied the blowtorch to that area and the drilled out remnants of the bolt fell right out.

 

[Kyle in Woodstock]

That's just what I have from Harbor Freight. I think I heated it for 15-30 seconds, though it may have been a little longer.

Here's what I was faced with:

I applied the blowtorch to that area and the drilled out remnants of the bolt fell right out.

Perfect, I plan on testing that out tonight and will let you guys know how it goes. Hoping it just falls out so I can finish grinding then get it painted up

 

[Kyle in Woodstock]

Ok, so since I can't seem to get IMGUR working while at work, I think I figured out how to do images from Wordpress instead.

Here is the front and back of both areas I'm having troubles with. There used to be bolts in these spots connecting the two horizontal frame connectors, one in front and one in back.
I had to cut the bolts off. I tried drilling them out without much success, but I likely need to get a new drill bit since mine have been around the block and are likely dull.
I tried hitting each side of these bolts with the small blow torch and that didn't seem to do much.

I think I will try to hit them with a new drill bit to at least get a clear hole from one side to the other, then hit it again with blow torch. Unless you guys have other suggestions.

**Ignore the spray paint on the fire box, I still have lots of grinding to do**

 

[Bruce]

A new drill bit might be the ticket. But, I would try to torch another time and after you heat it up good again, try punching it out. Not only should the heat help loosen it up, but it should soften the aluminum up a bit and help prevent the box from cracking. I have pounded out quite a few of those bolts in older grills and have only had one crack. Some I have whaled on pretty darn hard.

 

[LMichaels]

Grind it off flat. Then LIGHTLY center punch it. Then start with brand new drill bits. My tool and die maker buddy says titanium is best. Also when you do start off with one of these https://www.amazon.com/exec/obidos/ASIN/B07CML2DYM/tvwb-20 first. They will not wlak around when you're trying to start the hole. Another trick from my buddy. So amazed at how well this works BTW. You can even drill holes in steel rod if you start with those bits

 

[Bruce]

Larry, I didn't know those existed. I just sprung for a set. Got to be easier than trying to get a hole started with a 1/8 or smaller drill bit.

 

[Jon Tofte]

Yeah, I saved that for a future Amazon order, too!

 

[Kyle in Woodstock]

Grind it off flat. Then LIGHTLY center punch it. Then I start with brand new drill bits. My tool and die maker buddy says titanium is best. Also when you do start off with one of these https://www.amazon.com/exec/obidos/ASIN/B07CML2DYM/tvwb-20 first. They will not wlak around when you're trying to start the hole. Another trick from my buddy. So amazed at how well this works BTW. You can even drill holes in steel rod if you start with those bits

How do those things work? Is it like a punch where you tap with a hammer? Or do you put it in the chuck of a drill?

 

[Bruce]

Yah, put it in a drill like a drill bit. But they shouldn't snap in two like a regular drill bit and won't walk around when trying to start a hole like a regular bit will.

 

[LMichaels]

They sell them at Hazard Fraught BTW. That's where I buy them. You still need a good center punch. My friend explained it that, drill bits (especially smaller ones) will bend ever so slightly and flex which causes them to walk around no matter what you do. These do not. I was actually able to drill a roll pin hole in a 12mm axle for my walk behind lawn mower transmission with a handheld drill! They're da bomb

 

[Kyle in Woodstock]

Had some time tonight to hit the box a little with the angle grinder....still not totally finished with that. When you guys grind down the firebox, do you go down until you see the shiny metal color? I have burned through 2 brand new cup brushes from HF...one 3" and the other a 4". Maybe I'm pressing down too hard, but I feel like it would take forever if I didn't apply pressure. Also, do metal bristles fly off and stick into your jeans as you are grinding, or is that just me?

Here is some progress shots:

Here is a view of the new grates in the firebox. I still need to tweak them to get them 100% square, but I like them for the price I paid.

Also, to update on those stubborn bolts, I hit them multiple times with the torch and tried so new drill bits, filly was able to punch threw and then progressively used larger bits. The old bolts never did fall out, but I am at least now able to get a new nut/bolt installed there. Need to grind the area flat before doing so.

Wish I had a full day to knock all this work out, but it's hard to find spare time these days. Still need to finish grinding the firebox, then will lightly hit the frame and legs areas....hitting the rusty spots hard before spraying that with the rust converter.

I think I might have already mentioned this, but I'l going with 6" tight knot cedar for the floor, back and left side. I'll use some sort of sealer, but nothing crazy since I plan on keep it covered and eventually will have it under a covered patio as well.
I am going to re-paint and use the right panel since it's in good shape. The right side is the one that holds the propane tank, surprised at how little rust there was there.

 

[Bruce]

Being that it is your personal grill, I would grind until you are satisfied. But, for the outside, you probably want to take off the rest of the paint or it will look kind of strange after you repaint it. The inside is fine for a personal grill IMO. Maybe a little more if you are flipping it. I think part of your problem is that the gunk inside might have not been dry and hardened and is smearing as much as anything at this point.

I only use the 4" wire cup brushes from HF. You should be able to do a full grill with one, but yah, you will have to apply some pressure, but I woundn't think you need to lean on it so to speak.. Yes, I even get those damn things lodged into the skin on my arms if I don't wear long sleeves, which I don't in the summer. Definitely they get impaled into my clothes. So, if you ever see someone using one without eye protection, call 411 and tell them to put an ambulance on standby.

Looks like you are making some good progress. Keep us posted.

 

[Jon Tofte]

Yep, I agree with Bruce entirely, especially about safety. Protect those eyes at all costs, and strongly consider ear muffs, too. Finally, in my opinion, don't skimp and use super cheap paper "dust masks." I have found if you go up to the somewhat more expensive Harbor Freight ones with the little vent in the middle you are still getting off cheap but there is a notable improvement in junk being filtered out, at least in my experience. DON'T BREATHE ALUMINUM DUST! I may be OK with GrillGrates but not with that.

Along those lines, how does everyone here feel about using the mesh face screen and just safety glasses vs. goggles and possibly a solid face shield. In my climate fogging up is a huge problem, but I am sure most of you fact it as well. The mesh face screen sounds good, I just don't know enough to say it is adequately safe - in conjunction with the small safety glasses - to use while grinding metal.

AND WE DO THIS WHY?!!!

That's even with protection!

 

[Kyle in Woodstock]

Thanks, yeah I'm going to grind it all, just doing it little by little when I get time. I'm not going to be as picky about the inside, just making sure it's free of any paint the old owner might have sprayed in there.

I learned my lesson earlier this year building an arbor...made one small quick cut and small pieces of sawdust got in my eye, had to go to urgent care and then my eye doctor...wore a special contact lenses for the weekend and was all healed. Hurt like crazy though at first. Now I always wear safety glasses.

Being that it is your personal grill, I would grind until you are satisfied. But, for the outside, you probably want to take off the rest of the paint or it will look kind of strange after you repaint it. The inside is fine for a personal grill IMO. Maybe a little more if you are flipping it. I think part of your problem is that the gunk inside might have not been dry and hardened and is smearing as much as anything at this point.

I only use the 4" wire cup brushes from HF. You should be able to do a full grill with one, but yah, you will have to apply some pressure, but I woundn't think you need to lean on it so to speak.. Yes, I even get those damn things lodged into the skin on my arms if I don't wear long sleeves, which I don't in the summer. Definitely they get impaled into my clothes. So, if you ever see someone using one without eye protection, call 411 and tell them to put an ambulance on standby.

Looks like you are making some good progress. Keep us posted.

 

[Bruce]

When I was a kid, I was grinding rust on my car with a drill and wire brush. No glasses. I thought I just had some dirt in my eye but after two days, it wouldn't quit feeling like I had a grain of sand in there. Dr said a piece of metal burned into my eye. He numbed my eye and "scraped" it out. After the novacain wore off, it hurt like He11 for a day and then for a couple more days, it still felt like something was in there. Finally it healed and all was good. But, yah, had that been one of those javeline sized pieces coming off a 10,000 rpm angle grinder, I might be wearing an eye patch today.

And, no, I was not going "Black face", this is after a cook box grinding on a hot humid summer day. Not the worst I have looked after grinding cook boxes, but it shows what you have to look forward to if you decide to grind out a fire box.

 

[LMichaels]

Yeah I say some Easy Off and a power washer are safer. Glad you finally got that bolt drilled out