Summit 420 repair attempt


 
Eric-NH

Eric-NH

TVWBB Pro
So this was a freebie I grabbed over the weekend. I expected the rusted cook box since that's what they do, but figured I'd see if I could repair it and let other people in similar situations see what might be a solution to this known weak spot on the summit. Once I dig in to it I'll share my progress. My old Genesis gold c won't be going anywhere though, thing is nearly indestructible!
 

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Well that one's new enough that parts are probably still available for it if that's the way you want to go. It is a prime example of why not to waste your money on one new given it's condition, especially compared to your older Genesis Gold. I'm glad you got it for free and will be interested to see what you do with it.
 
Eric: That would be awesome if you could fab those cook box pieces out of stainless. You would have one heck of of grill if you do. Keep us posted.
 
The condition of that firebox is exactly what deters most from every trying to bring back one of these Summits. If you are able to work with metal, though, you might be the right person to overcome the obstacles. Do keep us posted!
 
What's everyone think about using aluminum? Seems easier to come by, and VASTLY cheaper. I wonder is 24 gauge is thick enough to resist becoming deformed with heat. Thinking out loud 😜
 
Eric-NH said:
What's everyone think about using aluminum? Seems easier to come by, and VASTLY cheaper. I wonder is 24 gauge is thick enough to resist becoming deformed with heat. Thinking out loud 😜
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Too thin. You want thick material to shield from burn through and something to provide a lip or shelve for the flavor bars

If cost is a factor you could use regular steel plate since you are most likely attaching it over the existing material
 
BPratt said:
Too thin. You want thick material to shield from burn through and something to provide a lip or shelve for the flavor bars

If cost is a factor you could use regular steel plate since you are most likely attaching it over the existing material
Click to expand...
I'm actually playing with the idea of completely replacing it. Partly to see if I can. I did wonder about plain steel and try to season it, like cast iron. My cast iron pans are seasoned well enough that I can now soak then for days in soapy water with zero rust issues
 
Eric-NH said:
I'm actually playing with the idea of completely replacing it. Partly to see if I can. I did wonder about plain steel and try to season it, like cast iron. My cast iron pans are seasoned well enough that I can now soak then for days in soapy water with zero rust issues
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It won't work (at least not for long). Heavy gauge aluminum might. But, your original instinct to use SS is the best
 
Anyone happen to know what gauge steel the porcelain coated part of the cookbox is? Might have found some cheap stainless but I'm worried it isn't thick enough. .022", so that's 26 gauge if I'm reading correctly
 
I might get it to practice on, do some trial and error. I can get 9 sheets of it, 28" x 20" for $40. I'd rather mess that up than expensive stuff!
 
Holy cow, I got word from Weber today that a new cookbox is in the mail and I'll see it in about a week! For me at least, it was super easy. Resisted the grill and then just asked if the pasta were available or covered under warranty. Attached pictures. No questions asked, the follow-up was just simply that it was approved and I would see it in 7-10 days! I'm still going to try to fix this so that maybe I can come up with a viable solution for other people that didn't have good luck with the warranty
 
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Just had another thought... POR15 makes a high heat (1200*) version. Could the rust be treated, then covered up with the patch plate? This should, in theory, keep any fumes out of the cooking space and, also in theory, stop the rust dead. Then the lower panel isn't needed to be completely replaced and the patch becomes more permanent rather than simply allowing a little more time before it eventually rots to the point of being structurally unsound. Thoughts? The patch might be seam sealed around the edges for high temp for grade rtv to further protect from possible off gas fumes
 
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