Rebuilding Weber Grills – Guest Post by David Somerville

Today’s post was written by David Somerville of and Quality Grill Parts. Like myself, David has a love for all things Weber, and he has a passion for finding and restoring old grills to their former glory.

It is not uncommon to find old Weber gas grills being put out with the trash or being sold on Craigslist for next to nothing. For me it is always very tempting to go grab these beauties, fix them up and give them a new home. That is how I ended up with this awesome Weber Genesis Gold C!

Picture 1

If you are in the mood to take on a Weber grill rebuild then here are a few things to check out on the prospective grill.

Some of the parts that routinely need replacing on old Weber grills are the burner tubes, Flavorizer bars, ignition system and grill grates. These parts are readily available for almost every Weber grill model.

Even if you have to replace all of these components you can typically do the repairs for under $150. Considering that a new Weber Genesis will run you around $800 this is a bargain!

Replacing these common components is also extremely easy. The hardest part of any of these repairs is loosening the screws that hold the burner tubes in place inside the firebox.

Since the screws the hold in the burner tubes have been exposed to high heat and dripping grease, etc there is usually a fair amount of corrosion that you will need to fight through.

Once you get the screws loose you can replace all of the components listed above in less than 10 minutes.

In addition to the burner tubes, Flavorizer bars, ignition system and grill grates there are three other components you should take a serious look at before you spend any money on parts. Depending upon the condition of these components you may want to decide to take a pass on a particular grill.

The Support Frame: If you are looking at a classic Weber like a Genesis 1-5 or 1000-5000 then there is a significant chance that the frame that holds the grill is starting to rust and wobble.

Sometimes the frame can be reinforced with some metal braces or creative woodworking. You will have a very hard time finding original parts to fix a frame this old.

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A weak frame is a safety issue that should not be ignored. The last thing you need is for your grill to collapse in the middle of a grilling session.

The Slider Rails: There is a set of slider rails that connect the grease collection system to the firebox. Replacement slider rails are easy to find and only cost a few bucks.

The problem is that the slider rails on Weber grills corrode starting at the point where they are screwed into the firebox. Getting these screws out to replace the slider rails is a major pain. Typically the screws have corroded into the firebox so bad that you have to take the heads off with a grinder then drill them out.

Always check the slider rails to see what type of project you are really getting.

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The Burner Controls: Don’t worry if the burner knobs are grey, cracked and ugly. If ugly knobs bother you then replacements are easy to find and cheap.

What you do need to check is whether or not all of the burner knobs turn freely. It is not uncommon on older gas grills for the burner controls to completely seize up.

While it is usually possible to get the controls to turn again using patience, a pair of channel locks and Liquid Wrench sometimes it will be a lost cause and an entire gas manifold will need to be ordered. If a new manifold is available it has the potential to increase project costs by around $100.

Don’t be afraid to take on a Weber grill restoration project. If the frame is solid, the slider rails stable and the burner controls turn free then you will have an easy and inexpensive project. If you don’t mind a little challenge and have the tools then the harder issues can also be fixed.

It turns out that one of the trickier aspects of rebuilding a Weber gas grill is finding the correct replacement parts. Even though Weber grill parts are readily available it is easy to get confused as to which parts to buy.

There are over 15 different versions of the Weber Genesis that have been produced over the past 20 years and the parts between these grills are not interchangeable. When you throw in the all the different versions of the Weber Spirit and Weber Summit it can give a person brain lock when they try to find the right Weber grill parts for their particular grill.

To help people get these Weber grills rebuilt I created the most comprehensive and user friendly directory of Weber grill parts on the Internet. This resource, is designed to get you to the exact part you need for your grill in three clicks or less.

If you need Weber grill parts then you can save yourself a lot of time by checking out the site. If I do not have the part you need you can use the contact form on the site to drop me a line. I am always ready and willing to help a fellow griller track down a missing part.

I hope you found this post on rebuilding Weber grills to be useful! If you have then it would be great if you would share it with your buddies.

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“Hot ‘N’ Fast” Pulled Pork


So I’ve been wanting to try my hand at “Hot ‘N’ Fast” pulled pork for a while now. For those of you who don’t know, “hot ‘N’ fast” barbecue is just what it sounds like – you run at a higher temp than normal, and therefore you’re able to cook your meat faster than normal.

For some folk’s, that would be sacrilege. Historically, the cuts of meat used for barbecue are tougher cuts of meat with a lot of fat running through it. By cooking the meat at a low temperature (typically between 225° – 250°F) over a long period of time, you’re able to slowly render a lot of that fat out of the meat without making it tough. Instead, the meat becomes as tender as your mothers love (Credit to Matt Pittman of Meat Church for that line).

However, you can cook at slightly higher temp (I was aiming for 325°F) and still have delicious, tender meat in much less time.

Anyway, onto the cook!


  • 2-3.5 lbs Pork Picnic Shoulders (I typically try to cook larger pork shoulders, but frequently I can only find small picnic shoulders like these.)
  • 5-6 TBSP of your favorite Sweet BBQ Rub – For this cook I went with:
  • 1/4 Cup Apple Juice


The night before I planned to cook my pork shoulders I trimmed off any the fat caps and seasoned with my rub. I’ve amassed a small collection of commercially available rubs, and while I like to try new and different rubs from different regions of the USA, it can be fun to make your own rubs. If you’re looking for a place to start, I strongly recommend “Meathead’s Memphis Dust“, from!

Once my shoulders where rubbed up, I wrapped them in saran wrap and placed them in my refrigerator overnight. While the shoulders are in the refrigerator, the salt that is in the rub is slowly bringing the moisture out of the meat. That moisture is in turn dissolving the rub and allowing the dissolved rub to be absorbed back into the meat.


I like to consider myself a student of barbecue, and in that spirit I’ve decided to cook exclusively with lump charcoal for the remainder of this summer. I have no real reason for it. It’s not that I dislike briquettes or anything. I simply wanted the challenge of cooking with a different fuel.

I set my grill up for indirect cooking, with my meat on one side and my charcoal and hickory chunks on the other. I lit two Weber lighter cubes on the one side of my charcoal so for it to burn like a wick from one side to the other. I learned this time around that the best way to do this is with one cube and to “bury it” at the bottom of my lump in the one corner.

I also placed a pan of baked beans under the two pork shoulders. I used Meathead’s recipe for Boston baked beans. FACT: PORK FAT MAKES BAKED BEANS AMAZEBALLS


At this stage I left both the top and bottom vents open on my Weber Performer 100% to let my grill come up to 325°F. Once my grill reached this temp, I choked back the top vent to 50% to keep it from rising anymore. I monitored the temperature of my pork and of my grill by using my handy-dandy wireless Maverick ET-732 thermometer.



I had to refill the charcoal basket at the two hour mark. Then at the three hour mark it was time to wrap the two pork shoulders in tinfoil with a splash of apple juice (about 1/8th of a cup per shoulder). By wrapping in tinfoil and adding the apple juice the pork shoulders begin to basically braise and become tender.



Another hour later (4 hours total cooktime) and these pork shoulders where done. I took them off the grill and wrapped them each in a towel (still wrapped in the tinfoil, of course). If it is going to be a while before you plan to eat dinner, you can keep your pork shoulders (or any large hunk o’ meat, for that matter) hot for hours if you place the towels in a dry cooler. But I was planning to eat these within an hour, so I just left them in a pan on my stove top.


After letting the pork shoulders rest for an hour and a half, it was time to pull! As you can see, the bones slipped out with no trouble. The meat was still hot to the touch, but not to the point of burning my fingers.

I served these to my guests on a hearty supermarket roll with a mustard based sauce that I just threw together with the leftover rub I had used on the pork, bottled mustard, apple cider vinegar, and brown sugar.

This was my first try at cooking anything using the Hot ‘N’ Fast method, and I have to say it was quite the success! I didn’t find this pulled pork any different from any I had cooked in the past. The only downside was that this was my first time wrapping a pork shoulder, and it did result in the bark not being a little more “moist” than I like it.

But it did beat getting up early on my weekend to cook pulled pork.

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Rosemary Garlic Pork Tenderloin “Steaks”


Okay, okay, I admit! These aren’t really steaks, but they are thick cut pork tenderloins, and when cooked they do look an awful lot like a steak, so I gave this recipe the name of Pork Tenderloin Steaks.

Pork Tenderloin, quite possibly one of the most under-rated cuts of pork. This recipe is super easy, but also super flavorful, and most importantly is near impossible to screw up.


  • 2 Pork ternderloin


  • 1/2 cup of olive oil
  • 1/4 cup of balsamic vinegar
  • 4 cloves of garlic
  • 1/2 TBSP of dried rosemary (use fresh if you have it!)
  • 1 TSP kosher salt
  • 1/2 TSP fresh cracked black pepper


To start things off, you’re going to grind your garlic into a paste. It really is pretty simple:

      Remove your garlic cloves from your bulb of garlic.
      Smash your cloves with the broad side of your knife and remove the peel.
      Coarsely chop your cloves.
      Once they are chopped up, begin to smear them into the cutting board with the broad side of your knife.
      About 5 minutes later, your garlic should look like the paste above.

Combine the garlic paste and remaining marinade ingredients in a large ziplock bag.


With a sharp knife, cut your pork tenderloin into individual 2″ thick steak portions, and place them into the ziplock bag with your marinade. Give everything a nice mix to ensure the pork is evenly coated, then set in the fridge for at least 2 hours, but overnight is better.


The next day, get your grill as hot as you can handle to make sure you get a good sear on your meat. I used my Weber Q 3200 with the assistance of Grill Grates to get the temp up in the 500°+ area. You can use any grill you like, charcoal or propane, just make sure you get a high heat so you can sear your meat.

Check your pork steaks after 5 minutes and ensure that they have a good sear, then rotate 90° to ensure you have a great cross-hatch mark!


After another 5 minutes flip those bad boys! If you’ve done everything right, your pork tenderloin steaks should look a little like in the picture above. Follow the previous steps of grilling your steaks for 5 more minutes, than rotating and finishing them off.

At this stage, check your internal temp with your Thermapen (you do have a Thermapen, right?). You’re going to want them to be around 135° internal. If you’re a little shy of the mark, move your meat to the cool side of your grill. I moved mine to the warming rack on my grill and turned my heat down low. Another 5 minutes and they where done.


I plated mine with some mixed veggies and mashed potatoes that my wife had made.

These pork tenderloin steaks are very moist and tender. You have the sweetness of the garlic, with the robust flavor of the balsamic vinegar and olive oil, and it all blends together with the rosemary, salt and pepper.

Try these at your next neighborhood barbecue, you will not be sorry!

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Pit Barrel Cooker Chicken

I’ve been the proud owner of a Pit Barrel Cooker for almost two years now. This cooker is exceptionally simple to use. It is the Ronco equivalent of grills. You load your charcoal basket, add some pre-lit briquettes, season and hang your meat, and bam – you’re on the bus to flavor town. Of all the simple meals you can make on your Pit Barrel Cooker, none is simpler than chicken.


The Pit Barrel Cooker (PBC) is a very basic cooker. Some may say it is the more attractive cousin to the Ugly Drum Smoker (UDS). The major difference is that rather than placing the meat on a grill grate (although the PBC does come with that option) the meat is hung from hooks on rebar over the charcoal. As well, the PBC does not have any vents that need to be opened and closed. This grill is a true set it and forget it style of cooker.

Because there is no vent to open and close, this also means that you have no way to regulate your temperature. In my experiences, the PBC runs a little hotter than I would typically cook. This also usually makes for shorter cook times. After some trial and error in the beginning, I found that the best way to cook on the PBC was to fill my charcoal basket with briquettes and light exactly 16 briquettes (not 15, not 17) in my Charcoal Chimney and add to the unlit briquettes.

Anyway, on to this cook.



I started by cutting the spine out of my whole chicken with a sharp pair of kitchen shears.


From here, I cut through the center of the breast; resulting in two halfs. I then inserted my meat hooks just under the wing on each half and then seasoned with some of the Pit Barrel Cooker All Purpose Rub.



While my chicken is marinating in the rub, I load my charcoal basket, light my 16 briquettes, and when they are ashed over dump evenly on my unlit briquettes.


After 1 Hour

I then hang my chicken inside the PBC (I also hung some chicken leg quarters I had in the fridge). Since this is a relatively quick cooker, the chickens are usually ready after 2 hours.


When I was nearing the end of my cook I whipped up a delicious barbecue sauce/glaze using Sweet Baby Rays and a Hot Pepper Jelly. I simply poured about 1/4 cup of barbecue sauce into a microwave proof bowl and added 1 tbsp of the pepper jelly. Then I heated it in the microwave for 45 seconds.



At the 1 hour 45 minute mark I removed my chicken and ensured that the temp in the both the breast and the thigh was 165°, I then added my glaze and placed back on the cooker for another 15 minutes to get sticky. From here I removed the chicken and served.

The chicken was fantastic. The meat was very moist with an excellent smoke flavor even though I hadn’t added any extra hard wood. The glaze was awesome, but wasn’t overpowered by the hot pepper jelly.

This is an excellent example of the types of simple meals that could be prepared on the awesome Pit Barrel Cooker. Please comment below if you would like to see more recipes for the PBC. I’ve cooked everything from Brisket to Pork Shoulder to even Bologna on this all purpose cooker.

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