Weber Genesis Restoration Experts... Need some input


 
T

TylerHonschopp

TVWBB Member
Hey guys, so I'm in the process of restoring a couple of early 2000s Genesis Silver Grills, and have 1 of 2 completely disassembled to the frame. It wasn't until I was at the end of my disassembly that I realized the metal grates/basket on the bottom are actually welded to the grill. So, in my previous restorations, I just used a palm sander and sanded/stripped as much of the frame as I could, which was pretty simple considering it was just a bunch of square/flat surfaces, but wondering if there is a better way with this metal basket at the bottom. Seems like it would be pretty labor intensive to try and sand all the nooks and crannies.

I'm currently looking at the following options:
-sandblast and powder coat the entire frame with a local powder coating shop (they quoted $100-125 for sandblasting only or $250 to sandblast and coat with high heat powder coat)
-just taping off the metal basket and sanding/painting the rest of the frame myself with high heat spray paint
-using some kind of paint stripper to remove all the paint?

Anyway, was wondering if others have restored models like this and what your process was. My only fear if I try to sand/paint everything but the basket is that the finish won't come out exactly the same and it'll look funny. I think I could justify the $125 on sandblasting but $250 is definitely a little more than I wanted to spend on a new paintjob.

Pic below of the current project. The serial number makes this one a 2003 model year Genesis Silver.

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DanHoo said:
The basket in the picture will come off. It may have corroded on making it appear welded.
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Really? Yeah it certainly felt stuck on and looking closely thought I could see a couple of small tack welds, but maybe just corrosion. I'll try and remove it once I get home today. That would be great if I can yank it off.
 
Basket on my 2001 Silver B comes off/out for sure. But my basket rests on the front and rear cross members.

Looks like the 2003 frame only has side cross pieces, and the basket has those narrow square connectors. Those could get stickier as compared to the prior design.
 
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TylerHonschopp said:
Really? Yeah it certainly felt stuck on and looking closely thought I could see a couple of small tack welds, but maybe just corrosion. I'll try and remove it once I get home today. That would be great if I can yank it off.
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Yes,

Here are two Silver B frames. 2000 on the right and a 2002 on the left and both bottom baskets come out.

I'd turn the frame upside down and hit each corner of the basket with a 2x4 to break it free.

@Bruce may have better suggestions as I'm sure he's come across this in his climate.

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DanHoo said:
Yes,

Here are two Silver B frames. 2000 on the right and a 2002 on the left and both bottom baskets come out.

I'd turn the frame upside down and hit each corner of the basket with a 2x4 to break it free.

@Bruce may have better suggestions as I'm sure he's come across this in his climate.

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View attachment 72140
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Great, I've got a rubber mallet that I'll use to smack it. Will report back later this evening!
 
NO, I doubt the basket is welded in. Possible, but unlikely and it was done after manufacture, not by Weber.

The metal part that is at the bottom slightly wedges under the left on right crossmembers on each side. If you push that metal piece back in towards the middle it will release the wire rack and it will slide up and then you can remove the rack.

The metal part that I am talking about is the one the arrow points to in the photo below. Just push that part inward and then lift the wire rack upwards. It should pop out fine.

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Thanks for the tips everyone. Realized the parts that looked like tack welds were actually just built up grease LOL.

Got the basket off and getting ready to start disassembly on the second Genesis I am going to restore (blue top). Hope to get a good amount of both frames sanded down this weekend.


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I just pulled one of those wire racks off a Silver B this morning. Unless they are rusted in place which is unlikely, they just require a good nudge with a thumb to unfasten them.
 
I have one of those exact duplicates torn down right now. I think it was a DT grill as well. I just painted the sand blasted cook box. I still need to do the lid though.
 
Hi Tyler, welcome. May I suggest working these grills one at a time. These being your first restores it may reduce confusion. Get the know the needs of each grill one at a time as their needs may be different. The only thing I do to more than one grill is clean cooking grates by dropping it in a bucket with detergent and baking soda.

Restoring grills will help you improve your mechanical skills and your troubleshooting skills. It's one of my favorite hobbies and during the nice-weather months, I debate whether to work on my grills or going on a bike ride or a walk in the forest.

I was you two years ago and with the help with the very knowledgeable and very generous men in this forum, I'm on my 25th grill. Learning something new each day. I take this opportunity to salute and thank all the contributors.
 
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Willard said:
Hi Tyler, welcome. May I suggest working these grills one at a time. These being your first restores it may reduce confusion. Get the know the needs of each grill one at a time as their needs may be different. The only thing I do to more than one grill is clean cooking grates by dropping it in a bucket with detergent and baking soda.

Restoring grills will help you improve your mechanical skills and your troubleshooting skills. It's one of my favorite hobbies and during the nice-weather months, I debate whether to work on my grills or going on a bike ride or a walk in the forest.

I was you two years ago and with the help with the very knowledgeable and very generous men in this forum, I'm on my 25th grill. Learning something new each day. I take this opportunity to salute and thank all the contributors.
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I am probably only going to do one at a time. I plan on repainting and finishing the black one first.

Here is my progress today on one of the frames. Sanding sure is a lot of work. Should be ready for paint soon.

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What kind of paint do you guys like for restorations? I believe I previously used krylon high heat max but I can't remember as it was a couple years ago.
 
Hey guys, sorry for the long delay between updates, been busy with other life events the past couple of months and the project was moved to the backburner.

I started working on the rehab again a couple weeks ago, and just got the final coat of paint on the frame last night. Overall it took 5 cans of Krylon spray paint to cover the frame, cook box, lid ends, basket, and manifold.

I already have all the new parts sitting in my garage, going to give the paint a good 2-3 days to cure completely before starting reassembly. Will update with more pics once the final assembly has been completed!

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