This post documents the restoration of a Weber Genesis Silver B propane grill. This has been our only grill since 2005, having been parked on balconies, decks, and patios in six houses in three states. If you ate a grilled meal at our house, it was cooked on this grill!

It was in pretty rough condition, both inside and out. The cooking grates and burners had been replaced two or three times. The starter worked exactly once, then never again.

The cookbox had been damaged, the front lip warped due to a grease fire in the porky days of 2012. The deformed lip prevented the grease tray from sliding completely into place. The grease bottom tray and liner bracket had turned to rust.

There was plenty of rust in the bottom of the cabinet as well.

I disassembled the hood and separated the cookbox from the cabinet. I removed the left shelves, front doors, but was unable to remove the right handle and condiment tray.

Weber provided me a new cooktop under the original 25 year warranty.

The cabinet and frame were scraped with an angle grinder and then sanded, primed, and painted with a glossy bbq paint.

The hood supports were cleaned inside and out with Simple Green twice. I then degreased them with brake cleaner and painted with a matte high-heat bbq paint. The hood was cleaned with Simple Green and polished. The “Weber” front emblem was sanded bright, and the thermometer and housing were polished with stainless steel polish. The support brackets and propane gauge were similarly cleaned, primed, and painted with a gloss spray paint.

I cleaned the plastic shelves and lid handle with Simple Green and then applied a few coats of 303 Aerospace Protectant.

The cabinet door panels had a plastic coating that had begun to fail. I scraped it off and cleaned with Simple Green and polished with stainless steel polish and 0000 steel wool.

Here are some after shots and our first meal.