Remove stuck manifold screws Genesis 1000


 
Jeff Hanson said:
No my screws came out with a gentle press on the impact trigger. The bosses themselves were missing a few chunks though and the oxidation was helping them stay in place
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Oh yeah I could see that happening. When the screws corrode they kind of swell a bit. Aluminum being brittle and it's all she wrote
 
Wondering if I'm off my rocker, but let's assume the "boss" is intact but now oversized. I wonder if it's feasible. Could you carefully drill all the way "up" and through the fire box, then use a longer threaded stainless steel screw (small bolt), nut and a washer on the inside? I've never had to deal with a bad grease tray rail so it's an idea that been floating in my head for a long time but have never tried.
My old Genesis I'd given my son in law finally had a bad rail last year but we did not use the old box because when the construction equipment smashed the grill it caused other damage to the firebox making it useless so we simply discarded it when we put the newer one in it's place.
 
That fix can be done larry as long as there is enough of the old "Boss" left to mount the slide rail at the proper height. Some times they crumble down to nubs and then you have to make even more mods to solve that problem.
 
Bruce said:
That fix can be done larry as long as there is enough of the old "Boss" left to mount the slide rail at the proper height. Some times they crumble down to nubs and then you have to make even more mods to solve that problem.
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Well that is pretty cool. Gonna keep that in mind should SIL's grill need that type of help
 
LMichaels said:
Wondering if I'm off my rocker, but let's assume the "boss" is intact but now oversized. I wonder if it's feasible. Could you carefully drill all the way "up" and through the fire box, then use a longer threaded stainless steel screw (small bolt), nut and a washer on the inside? I've never had to deal with a bad grease tray rail so it's an idea that been floating in my head for a long time but have never tried.
My old Genesis I'd given my son in law finally had a bad rail last year but we did not use the old box because when the construction equipment smashed the grill it caused other damage to the firebox making it useless so we simply discarded it when we put the newer one in it's place.
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I recall someone doing just that on here, and made tapered bosses, out of black pipe (I think) for the inside and outside. Looked pretty nice (and functioned beautifully) when he was done.
 
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Good to know Cody. Hard for me to think the old Genesis 2 with my SIL can go on too much longer :D Hell it's been through a very long time of ownership with me, 3 refurbs in that lifetime, it's been smashed flat by a loader, rebuilt (like the Phoenix) once again, and yet another firebox installed, not sure how much more it can go through :D
 
Cody Bratton said:
Weber sounds like a Timex - takes a lickin’ and keeps on ticking’!
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Well that one sure did. And early in it's life it even had caught fire so bad I had to empty a fire extinguisher in it (boy was that a mess). All because I had no clue grease collected anywhere :D It carried the remnants of that whitish green foam all over the place. Nothing would clean it off. Until it's first refurb
 
Jeff Hanson said:
I started stripping and cleaning my Genesis 1000 today. The wire brush did a pretty good job inside but I’m leaning toward bringing a pile of metal parts to a sandblaster. I also took survey of all the replaceable parts and ordered some new ones.

The rails for the slide out tray are pretty rusty but I was able to remove the screws without much effort on a small ratchet. The left side frame mounting screw looked like a rusty metal toothpick and the rusty hole in the cross bar where it was attached is big enough for a mouse to crawl in. I have seen the video on how to cut that out and replace with new stock, which I will do.

The drip pan and slide out tray and the flavor bars are all pretty beat up so I ordered new ones. The grill bars and hanging basket themselves are meh serviceable but I ordered some new ones anyway. The burners are rusty but ok except the rear one has a crack thru about 1/3-1/2 of the holes on the forward facing side, which explains the extreme hot spot in that back left corner, so I ordered some new pipes too.

The problem I am having is removing the screws attaching the brackets on the manifold to the fire box. They are size 5 metric hex head bolts, and I tried to break them free but am a little scared I’ll either strip them or crack the box.

Does anyone have any advice on how to free them up? Should I use penetrating oil, or maybe some heat? I have a heat gun but I could just fire up the grill too I guess. Pics of all this attached
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I went through this entire break down and a full frame-up restoration of my 21 year old Genesis Gold C this summer. These bolts came out ok for me but the one attached to the frame on the left side of the cook box looked like yours. It is very common. Long story short, the left side bolt had rusted completely off and broke inside the hole with very little pressure and lots of penetrating oil. Called Weber to discuss the problem and they sent me a new cook box under warrantee (25 years for lid and cookbox). I can’t suggest anything other than what you are doing in trying to remove those manifold bracket bolts but if they do break off, Weber may be able to help.
 
Brian Bonderud said:
I went through this entire break down and a full frame-up restoration of my 21 year old Genesis Gold C this summer. These bolts came out ok for me but the one attached to the frame on the left side of the cook box looked like yours. It is very common. Long story short, the left side bolt had rusted completely off and broke inside the hole with very little pressure and lots of penetrating oil. Called Weber to discuss the problem and they sent me a new cook box under warrantee (25 years for lid and cookbox). I can’t suggest anything other than what you are doing in trying to remove those manifold bracket bolts but if they do break off, Weber may be able to help.
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Welcome

the manifold bolts on the Genesis Silver/Gold series are not an issue. Weber uses stainless bolts in through holes. Either they come out or you just leave them in.

The issue you had is fairly common. You can grind the broken bolt flat and drill out. It does require some skill and tools beyond what is required for grill assembly and you can damage the box which is why Weber will cover it.

The older Genesis used bolts into blind holes for the manifold mount and sometimes a key head. They are prior to year 2000 so no warranty help. You would just grab parts from a donor grill
 
Looks great Jeff! Even though the wood may not be original, I think it looks really sharp and it does harken back to earlier gas Webers.

Your restoration journey is coming to an enjoyable ending - a beautiful vintage Weber and a lot of fun grilling ahead!
 
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