What does Weber do with the grill parts, bowls, lids, etc. that do not pass quality control? Grills with paint flaws and such that are still workable grills but just have visual flaws.
I would think the pretty obvious ones they would re-do, not so obvious, they would just ship out and roll the dice. Weber has an excellent 10 yr warranty on the finish and if a consumer complains they will replace it.
I know that their policy is to not sell any discounted scratch/dent merchandise, so like any production facility they decide whether it would be better to scrap or re-run it thorough the porcelain application process.
I have a lid for my 26 that was re-done, I bought a NIB 26 and a chunk of porcelain was missing. They replaced the lid under warranty after a rather long delay. I could see where a dent had been repaired and somehow re-surfaced. Phil's explanation sounds like what was done to my replacement lid.