Jon Tofte
TVWBB 1-Star Olympian
Just drill drain holes. Allows you to keep casters making the grill easier to move around. Also shoot some rust proofing into the legs. This is what I do. I use a product like this https://www.oreillyauto.com/detail/...ts-19574/hd-corrosion-inhibitor/06026/4176050 and it works great. It sprays in as a penetrating liquid and penetrates seams and so on. Unlike a tar or heavy wax it does not trap moisture it actually will displace moisture. I spray it into the door seams on my cars (provided there is no rust to begin with otherwise I use the Eastwood products I so often mention). It's a great product type to prevent rust. Once it penetrates it ceases flowing and will stay put. It works great also AFTER a rust repair to prevent further corrosion.
Larry,
Thanks once again for sharing your experience. Your advice has been a big help in learning how to do grill renovations better. I am going to try and find some of that O'Reilly rust proof stuff. Looks like I will have to drive a ways to pick it up, but it sounds like it is worth it!
As to casters, that is also a good idea. I think a lot of it has to do with where you put your grills and how much you move them. For example, when my in-laws still lived in suburban Chicago they kept their grill in the backyard shed a good long haul from where they wanted to grill. Four wheels there would have been a lot easier than any casters. "Permanently" sitting on a deck, of course, would be another story.
I see so many rusted-out legs in our coastal environment and even my own Performer lost one. I sometimes take my grills down a street in our unusually set up community, so my repair was to ditch the other caster, repair as much as possible with POR 15. I then used a PVC 1x1 inserted inside the leg that rusted partially off to give it some extra support. Then I just added an axle and regular wheels. Now I have a Performer that is a breeze to roll down the street and hopefully will be stable and usable for another 5 years or more. I would agree, though, that most people wouldn't need that. On the other hand, I still think that going to 4 casters was one of the several shortcomings of the Genesis 300 series. Whatever other issues the Genesis IIs have, at least they went back to the classic 2 wheels and 2 casters which I think is better.
Jon
HAVE A MERRY CHRISTMAS!
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