During the summer, we kept using our little portable nexgrill bbq on our back deck. We were tired of bending over and having limited cooking capacity. So I started looking on FB marketplace to find a cheap full size unit. I got a free one from a neighbor and as I was reading about repairs, I stumbled across a community of old dudes who restore old Webers. Low and behold, the next day an old Weber Genesis 1000 showed up on Marketplace and I went and snagged it. Thus began a 4 month adventure in learning how to restore this beast.
Day I got it. Wood was toast, lots of carbon buildup. Flavourizer bars are shot.
Disassembly! Took everything apart. Frame needed a full sanding and repaint. Only minor rust. No holes needed filling. The entire frame was treated with phosphoric acid before painting with a high heat enamel.
The porcelain enameled hood needed a good scraping as did the grease tray. Amazingly no rust on the tray! These are no longer replaceable. After scraping I degreased everything. Took a long time.
The fire box was in decent shape. Thick cast aluminum, made in the USA. Went through 4 wire brush cups on an angle grinder to take it all off. Stripped the outside as it was chipped and scratched. Repainted with stove bright 2000 degree paint.
The manifold was pretty gross. It got a full sanding, brass was polished, and all the valves were cleaned and regreased. Came out nice!
I ripped new cedar for the shelves and sanded the handle. Finished with multiple coats of boiled linseed oil.
Flame test with updated regulator to fit on modern propane bottles. No leaks! Ignitor works perfectly but the cookbox has a hole you can insert a bbq lighter into as well.
New flavourizer bars! This old school weber is sweet because it has the deep cookbox that accommodates 13 bars in total helping distribute heat.
Updated the tank scale to the modern one as I didnt want to custom print the measurement decal that used to be on the frame.
All done!