S-650 cookbox rust


 
Update on this 650 project: modified the old heat shield to fit inside the cookbox and adhered it with high temp RTV and clamped it until RTV is cured. If I had access to a brake I would have put a 90 bend at the top so the edge is not exposed. Finish putting this thing back together tomorrow.

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Joe DeCarolis said:
Update on this 650 project: modified the old heat shield to fit inside the cookbox and adhered it with high temp RTV and clamped it until RTV is cured. If I had access to a brake I would have put a 90 bend at the top so the edge is not exposed. Finish putting this thing back together tomorrow.

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Hoping you get this done. Make sure to show the results
 
OK got this beast back together with the laminated front panel. Assembly was straight forward until I tried to assemble the burner tubes. Problem was created when I laminated the inside panel there was a SLIGHT (like about 1/64") misalignment of the burner openings such that it made it difficult to pass the burners tubes through. Could have gone in there with a file and cleaned it out but I didn't want to damage the porcelain that is around the hole since that's where the corrosion starts. Finally got the burner tubes through with some finagling. If I had to do it again l'd make sure the inner panel is perfectly aligned before the RTV sets up. Rest of the assembly was routine. Its going to take along time to determine if this fix works. If I had done it to a compromised cook box you might see results right away, but with a new cook box it will probably take years.

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Another thing I noticed is the new cook box does not have holes for the 2 lower screws on the IR cover. Not sure if that was an oopsie on Weber's part or intentional. The cover is still attached by the 2 top screws.
 
Joe DeCarolis said:
Another thing I noticed is the new cook box does not have holes for the 2 lower screws on the IR cover. Not sure if that was an oopsie on Weber's part or intentional. The cover is still attached by the 2 top screws.
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Probably just a mistake. I'm sure you could drill those out if it was a problem.
 
Joe DeCarolis said:
OK got this beast back together with the laminated front panel. Assembly was straight forward until I tried to assemble the burner tubes. Problem was created when I laminated the inside panel there was a SLIGHT (like about 1/64") misalignment of the burner openings such that it made it difficult to pass the burners tubes through. Could have gone in there with a file and cleaned it out but I didn't want to damage the porcelain that is around the hole since that's where the corrosion starts. Finally got the burner tubes through with some finagling. If I had to do it again l'd make sure the inner panel is perfectly aligned before the RTV sets up. Rest of the assembly was routine. Its going to take along time to determine if this fix works. If I had done it to a compromised cook box you might see results right away, but with a new cook box it will probably take years.

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Looks good!

Is this some kind of patch panel you made, and if so, what material did you use for it?

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