Its an old Ducane Americana gas grill, it must be at least 6-8 years old. I was over at the girlfriends parents house when the offered me the old grill. I could not pass up on this opportunity to one have a gas grill that was larger than the one i had and two, it needed some work and seemed like a great project for me.
I wheeled the grill into the garage and found some tools to start taking it apart, not only to refurbish but also to fit in the car. While taking the grill apart, i was breaking bolts because they were so rusted and or actually part of the grill and had been exposed to high heat for long periods of time. The grill was in bad shape, alot of rust on the grill stand. The grill itself was very greasy therefore had alot of buildup.
Once i had it home, i soaked the grill racks and sprayed them with some heavy duty degreaser and let them set overnight.
The next day after work i went to Home Depot and got some metal brushes for my cordless drill, few more cans of grill cleaner, few cans of high heat black paint, 60 and 120 grit sandpaper. There I also had to get a few bolts and screws to replace the ones that i broke in the process of taking the grill apart and some were so rusted that there was a need for some new ones.
With the metal brushes for the cordless drill i was able to get all of the loose paint and rust off the entire grill. This also worked really well to get all of the grease build-up off from the inside of the grill. Once this was done i sanded the entire grill with rough sand paper to not only make a better surface for the paint to adhere to, but also to even out bumps from the paint that chipped off and rust. I then used the much finer sand paper to make the finish even more beautiful and a nice glossy shine once painted.
Once i was satisfied with the results i washed the entire grill, let it dry and then wiped off any residue with a damp cloth....now it was time to paint.
I chose a glossy black finish for the grill. I very lightly spray painted the grill pieces, let dry and repeated 4 more times for a nice coat of paint that would hopefully last a few summers.
I let the paint dry overnight before I began to put it back together. Note: When taking apart your grill label you bolts and screws. It will make your life alot easier when you start to put it back together.
My grill went back together fairly easy, i had just a few problems putting some screws and bolts in, but it was from the paint, so it was easily fixable.
Once it was all together i put the gas burners back in, the grate for the ceramic briquettes, the briquettes and the grill grates.
However i did not have a propane tank to test out the rehabbed grill, none the less a electric starter. My new neighbors have a grill with a propane tank. I didn't think they would mind if i used it for a few minutes. I hooked the propane to mine and turned it on. I turned one burner on and lit it with a long match, and the same with the other. It worked!!! I was so excited and really felt like i accomplished something that i really had a great time doing it.
This project took me about 2 weeks to complete, usually a few hours after work, the most work went into sanding all of the parts. I spent about 50-60 dollars on this project, the most expensive items was the spray paint. The bolts and screws are cheap, just bring them with you when getting new ones. Next year i will get a new grill grate and ceramic briquettes, the ones i have now will do for this summer.
Below are some pics of the finished grill, sorry i forgot to take pictures of what it looked like before, but trust me it needed to be rehabbed.