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Steve Hoch

TVWBB All-Star
I started taking my grill apart today. As you all know, it's a pain. For some reason I cannot get a socket or anything else on the bolt holding the fire box in. Annoying, because I'm pretty sure the nut inside the box will turn.
 

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Bruce

TVWBB 1-Star Olympian
Put a vice grips on the inside nut. Then put a 7/16" wrench on the outside head of the bolt and twist it until the bolt comes out or twists off. If it twists off and is frozen inside the cookbox, then you will have to deal with drilling or pounding it out. Some may suggest penetrating oil a few times over several hour or even days, but, in my experience, that won't do anything but delay the inevitable.
 

Steve Hoch

TVWBB All-Star
Will do, I think I'm going to concentrate on the frame next. Now that it's apart I can see where the rust is that I thought wasn't there!
 

Steve Hoch

TVWBB All-Star
Over the weekend I decided to power wash the lid, firebox, and end caps. The end caps came out the best. I'm probably going to look into having these parts sandblasted and maybe even powder coated 20210802_163036.jpg
 

Steve Hoch

TVWBB All-Star
I also completely disassembled the frame.I decided to do this after I tried to tighten the lower frame supports and the connectors disintegrated. I already ordered new ones. 20210802_163057.jpg
 

Steve Hoch

TVWBB All-Star
This was the worst of the rust. Luckily, it's on the underside of the cook box rail. I may also look into having the frame sandblasted. 20210802_163132.jpg 20210802_163132.jpg
 

Bruce

TVWBB 1-Star Olympian
Rather than new brackets for the frame pieces, you should probably just look into having them welded. That rust where you say is on the cook box rail is pretty bad. Where exactly is it? You might want to consider replacing that piece.
 

Steve Hoch

TVWBB All-Star
The brackets are all fine, the bolts all came out no problem. It was the star connectors in the cross braces that were all shot. I know the rust looks pretty bad in the picture, but it's not through. Here is a better picture of the frame piece that it's on. 16279432467822594725779382078216.jpg
 

Steve Hoch

TVWBB All-Star
Ok, I took a grinder to that rust and there's the hole. What do I do now? I can probably fill the area with some epoxy and sand it down for painting. Powder coating is probably out of the question over a repair like that. I have another grill ( big surprise here) I could cannibalize the part from, but don't want to because that grill is too nice and I'm currently using it. 16279476966525905075213867990471.jpg
 

Bruce

TVWBB 1-Star Olympian
Where that rust is, you are probably OK if you clean up the rust and repaint it. You might want to consider some POR15 or Eastwood Rust Encapsulator for that area. A welder could fill that in and grind it down smooth for you as well.
The other option is to keep your eyes open for another donor grill. Those older ones pop up for free or cheap pretty often.
 

Tim Snyder

TVWBB Super Fan
Welding and grinding the rust would be the best prep for powder coating, but they also make powder friendly fillers for rough spots like that.
 

Steve Hoch

TVWBB All-Star
Thanks Bruce, is it ok to paint over light surface rust, or does that end up being a problem? I was just looking for another grill yesterday, although I'm not sure why. I guess you can't have too many parts on hand for this kind of thing.
 

Steve Hoch

TVWBB All-Star
Welding and grinding the rust would be the best prep for powder coating, but they also make powder friendly fillers for rough spots like that.
Thanks, that may work too. After all the money I already spent on new parts, the thought of having to pay someone to fix this makes me want to scream!
 

Bruce

TVWBB 1-Star Olympian
Thanks Bruce, is it ok to paint over light surface rust, or does that end up being a problem? I was just looking for another grill yesterday, although I'm not sure why. I guess you can't have too many parts on hand for this kind of thing.
You can use one of the Rust Encapsulators. That is what they are made for and they do a great job. But it is usually best to remove the rust and reprime/repaint if it is feasible.

We see a lot of new members here who join after they start a grill rehab project. It is too bad that they don't join before starting a project as there is so much great knowledge here and we probably could have saved you a whole lot of money and time to get you to where you are right now. But, it is part of the learning process and most of us here started out just like you did and spent too much money and time on their first rehab or two.
 

Steve Hoch

TVWBB All-Star
The funny thing is that I got started after watching a YouTube video by Chris on cleaning/lubing the manifold. The next one I saw was a guy named ESOX07 (I think) fixing the frame on a weber grill. I didn't discover you guys until I was googling part numbers for my restoration. I was looking for the tank gauge sticker and I clicked on the tvwbb. I still didn't know until recently that you are ESOX07 (I think). Anyway, I at least learn from my mistakes and will figure this out! Plus, if I hadn't owned this grill since new, I wouldn't be thinking with my heart instead of my head. I have still learned a lot from everyone here and will continue to post my results even if they are wrong!
 

Steve Hoch

TVWBB All-Star
I've known that for about a week now. I actually tried to find ESOX07 on here thinking that anyone that could do that kind of work must be member of this group. It made me laugh.
 

 

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