How to Rebuild a Weber Grill

Using flavorizer bars can help reduce grill flareups.

Weber grills first came on the market in the early 1950s as a charcoal grill. In the early 1980s Weber expanded its product line to gas grills. Weber gas grills use a burner tube system instead of lava rocks. A well-built gas grill can last for 10 years or more. With a little effort, you can rebuild a Weber for far less than buying a new grill.

Things You'll Need

• Weber burner tube kit
• Weber flavorizer bar kit
• Phillips screwdriver
• Adjustable wrench
• ¼ cup of water
• 3 to 4 drops of liquid soap

Instructions

Preparation

1. Make sure grill is turned off and cool to the touch.

2. Disconnect the gas supply at the source by unscrewing the connector from the tank.

3. Open the grill lid and remove the grates covering the grill surface. Clean and set aside.

4. Remove the flavorizer bars. These are the long inverted V-shaped plates that cover the burner tube. They're not attached, but simply rest on edges above the tubes. Discard.

5. Remove control panel and burner control knobs on the right side of the grill. The knobs can be pulled up by hand. Using the Phillips screwdriver, remove the screws in the trim surrounding the control panel. Lift and remove the control panel and set it aside.

Manifold Frame

1. Locate the metal frame that looks like two T's side by side after you've removed the control panel and knobs. This is the manifold frame the gas goes through. Unhook the brackets on the outside of the manifold frame.

2. Use the adjustable wrench to loosen the nuts on the screws that hold the manifold frame to the main cooking box on the grill.

3. Slide out the manifold frame carefully. Set it aside.

Burner Tubes

1. Remove old burner tubes by sliding them out individually. The burner tubes are round with a flat piece on one end with a small notch. The notch slides between a screw and washer. The screw and washer are attached to a small plate. These serve only as a guide, so you don't need to loosen screws to remove the tubes.

2. Lift and twist tubes slightly once you have them out from under the screws. This separates the burner tubes from the crossover tube bar. The crossover tube is a round thin tube inserted in the ends of the burner tubes. Remove burner and crossover tubes from the main cooking box of the grill. Discard old tubes.

3. Slide new burner tubes through openings in the main cooking box. Insert the crossover tube into opening at ends of the burner tube. If you have a three-burner tube model, slide the tube with no opening on either end into notch on crossover tube. A single row of gas portholes on tubes should be facing up.

4. Slide tubes back under the screws and the washers.

5. Reinstall the manifold frame.

6. Add new flavorizer bars atop the burner tubes. Put the cleaned grates back on the grill.

Testing

1. Test for gas leaks before reinstalling control panel and knobs. Reattach gas supply to the source.

2. Mix the liquid soap and water together.

3. Turn on gas supply at the source, but don't ignite the grill.

4. Wet the connections, using your fingers, between manifold frame and burner tubes with soap and water. If it bubbles, there's a leak. Retighten all connections with adjustable wrench and retest.

5. Reinstall the control panel and knobs.

References

• Weber.com: Weber Manuals