Thoughts on fixing cracked cook box


 
H

Hank Green

New member
Hello, this is my first post here. A neighbor had rolled a 2009 Genesis E310 to the curb, free to a good home. Having only 5 grills I figured heck why not make it an even half dozen. The favorizers are shot, the igniter does not work, and it has the dreaded cracked cook box at the hinges. The guy got it from his in-laws so it is not covered.
Has anyone ever fabricated a fix for these knocked out places that catch the lid ears? I was thinking of bolting a steel bonding strip to catch the lid ears. Anyway if this fails do you think it is worth buying the new cook box at about 400 bones?

Thanks
Oh my other grills are
Original Grilla
Weber Q100
Weber kettle
Charbroil something or another
Force 10
 

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l absolutely do not think it is worth investing in the new cookbox. This is a classic case of diminishing returns. You have other grills and this one still basically works. I would have other things to blow $400 on before improving the performance of grill #6.

Of course, everything has its price. If you could get the cookbox for free or nearly so, that would be a whole different story.
 
Bolting a top cross member seems pretty inexpensive, I say give it a shot! The attachment of the lid ”ears” might be a “fun“ challenge but, where there’s a will, there’s a way. In this case, I do agree with Scott, don’t drop a ton of money, make it a “conquest”, a truly salvage operation for the fun not for profit project.
I’ve done that kind of thing in the past and it’s rather satisfying to get something in operating condition in an unorthodox manner.
No, don’t spent a ton of money!
 
Thanks! I'll swing by the hardware store this weekend and pick up a piece of bar steel. I think I may need to grind that lip on the edge of the box to get the bar flush with the top edge to catch the lid ears.
 
Yah, those grills almost always are totally rusted out inside the cabinet. I would wait for a cheap or free one to pop up on the fore sale/free sites. Then just swap out the cook box.
 
Hank Green said:
Thanks! I'll swing by the hardware store this weekend and pick up a piece of bar steel. I think I may need to grind that lip on the edge of the box to get the bar flush with the top edge to catch the lid ears.
Click to expand...
Don't forget to allow for the thickness of the bar. The lid may not stay open, or may have a tendency to want to fall closed with the slightest jiggle. The bar may be better mounted on the inside.
 
Ed P said:
Don't forget to allow for the thickness of the bar. The lid may not stay open, or may have a tendency to want to fall closed with the slightest jiggle. The bar may be better mounted on the inside.
Click to expand...
Good point and if I mount it inside I might be able to bend a right angle into it and put a few bolts through the side.
 
Well I think I got it. The bar steal on the inside was just too far in and the lid still went back further than I liked. I drilled and added a stop bolt to the bar and it came out perfect!
 

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Hank Green said:
Well I think I got it. The bar steal on the inside was just too far in and the lid still went back further than I liked. I drilled and added a stop bolt to the bar and it came out perfect!
Click to expand...
Nicely done Hank. It's a little late to ask, but is that BBQ > 10 years old? If not, it might be covered under warrantee
 
Mye320 had a warped cook box, i registered it online w Weber called the next day and after I took some pics they sent a new one!
 
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