Rather than spending hundreds of dollars on a new grill, try renovating an old one yourself. Even a rookie handyman can tackle this challenge. The money you can save by fixing up your old grill will be well spent on those delicious cuts of meat you’ve been missing. So, set aside a few hours, get your tools ready, and prepare to bring your old grill back to life. You’ll be sinking your teeth into porterhouses and baby back ribs in no time!
Clean-up
Begin your restoration by giving your grill a thorough cleaning. This will allow you to uncover any rust spots or damage that will need to be replaced or repaired later. Scrape the inside of the grill with a wire brush to remove any loose soot or debris. A shop-vac makes cleanup a breeze especially in tight places, corners, and around burners. To clean up excess grease or stubborn debris, use soap and water with a wire brush.
Grill grates can be cleaned in much the same way as the rest of the grill interior. However, using soap and water is generally not needed. Cleaning the grate with a wire brush while hot is usually the best method. One very important, yet often overlooked part of grate maintenance is oiling the grate. There is no right or wrong way to do this as long as the cooking surface of the grate is covered with oil. This will season the grate, protect the metal, and keep your food from sticking.
The outside of the grill can be sprayed off with a water hose. If there is an excess of dirt or grime, again, use soap. If the outside of your grill has rust or the paint is chipping off, don’t worry! You can fix that.
After cleaning your grill from inside to outside, begin removing any bolts, brackets, gas lines, accessory racks, or handles that come in contact with the outside of the grill. This will prepare the entire exterior of the grill for painting. Trying to paint around these areas will lead to cracking of the paint especially around handles and bolts that get moved with constant use. (This is a good time to look over the grill and see if any parts need to be replaced.)
Lightly sand the exterior surface of the grill. For areas that have rust power tools may be required. They make this part of the restoration not only much easier, but much more fun. My grill had several rust spots on its underside. I used an angle grinder with a low grit sanding attachment to remove most of the rust. Then a high grit sanding attachment finished the job. Circular wire brush attachments are very handy too. Wash the exterior with water and immediately dry it. Cover any holes or cracks with tape or paper to prevent paint from getting inside the grill. DO NOT GET PAINT IN THE INSIDE OF THE GRILL! Toxic fumes from the paint can be released when high heat is built up in the grill. Now you’re ready to paint.
Not all paint is the same when it comes to barbeque grills. I HIGHLY recommend using a paint that is designed for high heat applications. There are paints on the market specifically for grills. Follow the instructions on the paint can (i.e. use smooth, even strokes about 12 inches away from the painting surface, etc). Several coats of paint will ensure the protection and increase the lifespan of the grill. After the paint dries, replace all the parts you removed and any new ones that needed to be replaced.
After taking the time to renovate your old grill, don’t let all that hard work go to waste. A few simple maintenance steps will keep your grill in excellent shape and prolong its life. First, keep your grill grates clean. Use a wire brush to clean before and after cooking. Don’t forget to oil! That is the most important part. Second, if using a charcoal grill, regularly remove ash and old coals. Finally, be sure and use your grill. I know that sounds funny, but heat from the grill is the best method for keeping the interior and grates clean. Periodically, replacing burners, grill grates, or other parts may be needed. For those avid do-it-yourselfers, replacing existing parts can often be accomplished in a more economical way just than buying manufacturer’s parts. I replaced all my grill grate mounts by cutting a $5 piece of angle iron into several L-shaped pieces. Be creative!
