Repairing the cook box


 
Both screws from the manifold broke off inside the cookbox. What size of drill bit should I use to hollow them out?
 
Part number for 2007 Genesis E310: 67728
Part number for Spirit E310: 91424

Source: https://www.weber.com/US/en/help/schematics/browse/3741001 and https://www.weber.com/US/en/help/schematics/browse/4421001

I also cross referenced with https://www.ereplacementparts.com/cook-book-p-1476397.html
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Update: I found a donor grill. This is the 3rd grill I pick up to repair the one I found behind the MetroNorth train tracks. I wonder what is the highest number of donor grills that anyone remembers gathering parts from in order to have one final working grill. Frankenstein for sure.
 
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It turns out there's a whole "How To" on removing screws from Cookboxes I had not seen. Thanks Bruce and the others who contributed to it.

tvwbb.com

HOW TO: Cook Box Frozen Bolt Removal

WHAT: This is a How To on one method of removing the frozen bolt in the cast aluminum cook boxes of various Weber grills. WHY: The cook box mounting bolt as well as the manifold mounting bolts tend to corrode due to aluminum and steel being in close proximity to each other. The dissimilar...
tvwbb.com tvwbb.com
 
My neighbor will be keeping this grill and he ordered a brand new cookbox. When we tried to mount the manifold, the holes were not big enough so we used a drill and widened them a bit.

The cookbox is brand new, which seemed weird.
 

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I've run into this problem with other things. Since those holes are threaded you don't want to drill them out and shouldn't have to. What usually works is to put the screws in by themselves first to open the holes up better. Then you put it all back together. I'm assuming that the cookbox has threaded holes of course.
 
Steve Hoch said:
I've run into this problem with other things. Since those holes are threaded you don't want to drill them out and shouldn't have to. What usually works is to put the screws in by themselves first to open the holes up better. Then you put it all back together. I'm assuming that the cookbox has threaded holes of course.
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I was advised to drill them out and use a stainless hex bolt on the inside, nut and lock washer on the outside.

I drilled mine to 1/4 inch
 
DanHoo said:
I was advised to drill them out and use a stainless hex bolt on the inside, nut and lock washer on the outside.

I drilled mine to 1/4 inch
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I know, I was one of the people that suggested that. I think yours was a different situation in that this is a brand new cookbox. Yours had the screws break off inside after 25 years.
 
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