Genesis Junior Burner Tube Fabrication How-To

[Winz]

I recently acquired a red Genesis Jr that was well taken care of, but one of the burners had a 7" crack in it and was leaking pretty bad.  Weber does not make burner tubes for the Junior, but a quick search of the WKC lead me to a way to make new ones for my grill.  Many thanks to @pbe gummi bear as he has done this before and was my coach for the project.


I started with new burner tubes:





In this kit, you get three burner tubes.  You only use the two on the right.  The one on the left is a middle tube and does not work for this mod:





You can see how much longer the new tubes are compared to the Genesis JR:







I cut the tube using my angle grinder.  Gummi said to cut it a little longer than you think you need which was good advice.







After cutting, I placed the end of the tube into a vice and crimped the end.  Make sure the crimp in aligned with the burner tubes so that the flame will point the right direction when you are done.





Here is the new burner after the vise work.  I used the cut off wheel on my angle grinder against the end of the cut.  It pretty much sealed the end so that gas does not flow through.








To cut the cross burner hole, I used a drill bit smaller than the cross burner tube, and then used a reamer to make it fit exactly right





Rather than notching the end, I simply drilled a hole to fit the screw that holds the burner tube in place.





There you have it.  Nice blue flames and a set of burner tubes that should last for quite a while.





Had to top it off with some new flavorizers





Project is coming along nicely!







If you are thinking of a Gen Jr rescue but are worried about the lack of burner tube supply - don't be.  These were quite easy to make using a vice, drill and bits, 4" angle grinder with a cut off wheel, and a reaming bit.


Winzeler

[jcnaz]

Wow, that looks terrific!

Thank you for the tutorial, it will keep a few more of these old grills cooking.

[pbe gummi bear]

Excellent work, @Winz!

[JEBIV]

I want a junior so bad

Sent from my SAMSUNG-SM-G930A using Tapatalk

[Bob BQ]

Excellent!  Thanks for the pics, @Winz.  The restore is coming along nicely.  Let me know if you want to get rid of your Junior's original wheels.... thanks!

[DellJones]

Very Nice!!!! Thank you for sharing. I needed a few sets of burners


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[Dave in KC]

Great looking Jr. 

[MacEggs]

This is fantastic! Thanks for sharing, @Winz .

[Brian ATL]

Really nice job so I assume you took the risk since you drilled a hole in the flat part of the burners to remove those screws.  You are way more brave than I am. 

[crowderjd]

Great info.  Thanks!