Weber Summit Gold D4 Restoration


 

JeffreyM

New member
Inspired by some recent threads, I am attempting to restore my personal Summit Gold D4. I originally purchased the grill from Weber in 2006. Two years ago I replaced the complete electronic ignition, flavorizer bars (OEM $$$) and burners. At that time, I noticed that the front of my firebox had rusted through in a few places - as several posters here have noted is the weakness of these grills. My model has the stainless steel insert where the burners go through. I figured I was out of warranty because that portion of the firebox was not cast aluminum so not subject to the 25 year warranty.

I recently read some threads here where Weber was providing warranty replacements for the fireboxes on these models. Expecting to be rejected, I made a claim on the firebox and also on the lid that had rust through on the liner. A quick response from Weber granted my claims and a new firebox and lid are being shipped out! While the design that led to these issues is a Weber failure, the support is a Weber success story.

Now the question is whether I should acquire a Platinum donor grill with all stainless steel cart and panels to reassemble my grill in?? There is one for sale for $200 not too far from me but it is a NG A4 (no side burner and no rotisserie). This would also give me an opportunity to convert to NG which is something I have wanted to do for awhile. I think I would just need new orifices. Then I would have a great almost new grill that would surely last another 10-15 years.

Question is whether $200 is too much for a 15 year-old donor grill and whether it is worth the trouble.

Pictures of my set up attached.AC2E365F-BDA0-4C3D-9932-2B9E4FA5058B.jpeg6CA38154-1BC5-48E2-B231-926F2D474ABC.jpeg343A5137-22A0-4D53-A0DA-2355613299D8.jpegF2E794BB-D797-41AE-B727-683CCFB08C7B.jpeg56EC3C60-DD0A-4474-A91F-BFA5AE1BC880.jpeg242A63F9-6EFF-45FB-8423-025079010072.jpegE4306AF8-4846-4A14-BBA5-95DE920BBF44.jpegAC2E365F-BDA0-4C3D-9932-2B9E4FA5058B.jpeg
 
If I am following you, the pictures are what you have now, but Weber is sending you an entirely new firebox. If so, then I could see spending the $200 to upgrade to a Platinum. The stainless framework AND especially the all-stainless cabinetry below would be worth that for a personal use grill in my opinion.

I will stay out of the LP/NG stuff, but with a NG manifold you would solve most of the issues. I will let Larry weigh in on the side burner, but I think I have read where he said you could probably get by with the LP one using NG - NOT, of course, the main burners which will be fixed by swapping the manifold.
 
Jon - yes, the pictures are what I have now and I have a new firebox and lid coming. I do have some minor rust on the bottom panel of the enclosed cabinet but none apparent on the frame. I might save the $200 to fix the roto burner that wont stay lit instead of picking up the platinum though. Your comment made me think the NG manifold wont work for me because I have the smoker burner that is part of my manifold and would not be on the A4 donor grill manifold.
 
Try to haggle him down. Offer $100. Then try to sell the extra parts you don't need. These thermaset tables always sell good on ebay. And if the other one has decent flavorizer bars keep them for spares. New ones are really expensive and probably not available for much longer.
You could swap the NG orifices into your manifold. You would need to extra ones for the smoker burner and the rotisserie burner.
 
Okay - missed out on the platinum frame - gotta move fast. Dissemble everything yesterday and frame is pretty good but bottom panel has lots of surface rust and cracking. No holes or even close to holes yet.

any recommendations on next step to stop the rust? I could grind it down or encapsulate it and paint over it. Don’t really care about appearance.

new roto burner and various parts ordered.
 

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Yep, you are probably looking at grinding, sanding and repainting at the least. A coating of rust encapsulator wouldn't hurt either.
Keep us posted on your progress.
 
Yep some light sanding and hit it with POR15 or Eastwood Rust Encapsulator and then hit it with black Rustoleum. Speaking of Rustoleum, many folks especially those "younger ones" here have no idea why Rustoleum is called that and why it was so "special" back in the day. Well it was due to it containing fish oil. Yep, the original Rustoleum product had fish oil in it. And let me tell you all that the smell would raise the dead and cause your nose hair to fall out. I don't know what makes it better today if at all but back in the day it was fish oil. Also it only came in like 3 colors or so as well
 
There is enough problem with vermin being attracted out our grills. We don't need them smelling like fish as well.
 
hello where are you located i have a natural gas grill just like that with smoker and roisterer and side burner they used as a built in so no frame but all the natural gas stuff
 
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Some more progress picks. Prepped frame and panels for Eastwood rust converter, then encapsulate and then rustoleum high heat ultra black. Cabinet floor was worse than I thought. May just buy a replacement. I should have bought the platinum donor grill for $200. Would have been cheaper than new floor plus paint (not to mention labor). Oh well.

Also ordered new roto burner since having that working is the main draw of this model. My Smokefire is a suitable replacement for the smoker functionality when it is working.5C67FD25-8EEC-4A2F-B141-5AED5B7429F7.jpeg61585427-8D72-4165-BA5B-6261F89FDD75.jpeg
 
New parts arriving. New firebox and lid. Interestingly, the firebox label says it was produced in 2016. Lid was 2018. Gonna have to restore the old emblem rather than use the new shiny one provided with the new lid.

Question - the bolts that attach the firebox to the frame broke when disassembling the grill and need to be replaced. What size are the bolts and nuts? Should I go with stainless steel? Is there any resource that will tell me what hardware I need if I wanted to replace all hardware with ss?

Firebox.jpgFirebox2.jpgLid.jpg
 
I don't know size but on a grill if you can find stainless go that way. Also be sure to use Never Seize wherever steel bolts get screwed into aluminum
 
Download the owner's manual from Weber.com. It will have a hardware list with sizes and specs. That will get you most of the way there.
 
I would say you are well on the way to a super nice grill. If another Platinum comes along for a good price, I would grab that to upgrade the lower part. Even so, you will be looking good for quite a while.

Looking at that stainless front piece, it doesn't look to me like it would such a big deal to have two stainless flat plates made with openings roughly the size of the burner openings and use them to sandwich a failing front with the reinforcement pieces on both sides held tight using rivets.
 
Progress Update 1

Frame sanded, prepped with Eastwood rust encapsulator and painted with Rustoleum high heat ultra. Assembed with new bottom panel direct from Weber and all new stainless hardware. New wheels all around.3BE2C2FA-0488-40F3-8C97-BEAFC37CA9A9.jpeg
 
With all those new parts and the excellent work on the frame, I would say with some good care you will have a great Summit to use for years to come.(y)
 
Update 3

New rotisserie burner assembly and install 366A27D6-C0C9-4799-9278-195B488860F1.jpeg44A4C566-9AE3-4C90-9175-8E0484802118.jpegC861EB61-A7EE-43A0-A84F-9F82A9DD3AEE.jpegA07D6F8F-C775-4975-BC83-4DF221E24792.jpeg6E7E5F71-B7C8-4654-8B06-718D7853543E.jpeg
Weber changed the layout of the ignition assembly
 

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