Weber Kettle Club Forums
Grill Talk => Gas Grills & Electric Kettles => Topic started by: SixZeroFour on July 20, 2016, 07:33:24 PM
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I love the original 1000-3000 model Genesis gassers. Factor in reliability, serviceability, performance and looks and it's probably my favorite gas grill of all time... So when a fellow club member approached me about doing a top-to bottom restore on one I was both excited and honored to get started. I've done multiple refurbs in the past but never anything even close to this...
The build was planned start to finish with every detail laid out in advance. A side burner was not desired, but we wanted to go with all wood slats so 2200 Platinum fit the bill perfectly. The 2200 is somewhat rare in a sense that it has wood slat surfacing and swing up tables on both sides of the grill giving you a ton of surface area to work with. It also has two levels of Flavorizer bars, 13 in total, for extremely even heating across the whole cooking area.
In the end 4 or 5 different grills were cannibalized in order to pick and choose all the best parts. The frame was completely disassembled and sandblasted down to bare metal then powdercoated for a like-new long lasting finish. The firebox was also completely blasted inside and out and looks like the day it rolled off the showroom floor. It has new burners, new SS Flavorizer bars, new starter module and electrode, new cast iron grates, new lid swing rack, new warming rack, new grease pan, new grease tray, and all new stained and finished slats. I was also fortunate to have found a like new reversible griddle, complete rotisserie kit, and an original user manual\cookbook... oh and of course a cover 8)
It will be a bit difficult to watch this one roll out of the garage but thankfully it couldn't possibly be going to a better home. A big time Weber fan and just an all round great guy! Thank you so much for allowing me to be a part of this project and I hope you are as happy with the results as I am.
[emoji106]
The process:
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Thanks for looking!
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Eh, if your into that sort of thing.... AND I AM! Holy crap that thing is beautiful!!! Excellent job....wow!
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Excellent work, Matt. Can I employ your services one day too?
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Wow,Great Job!!!.......Think i will sandblast mine aswell ,powercoat looks great!!
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Beautiful work! That should last another 20 years. I would love to have the durawood shelves and handle tho. Here in Nevada the wood is in constant need. I have a 1000 that needs all of it. I wish it was still available.
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(http://i1314.photobucket.com/albums/t562/sttab77/tapatalk_1431175743948_zpsiyjtjvad.jpeg) (http://s1314.photobucket.com/user/sttab77/media/tapatalk_1431175743948_zpsiyjtjvad.jpeg.html)
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What skill and attention to detail; your work is of the highest quality. Well done!
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Very nice! How long did that take? What was some of the harder pieces to deal with during this project?
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Excellent work, Matt. Can I employ your services one day too?
Of course... almost sounds like you have a project in mind? 8)
Very nice! How long did that take? What was some of the harder pieces to deal with during this project?
In total a little over 2 months. It was substantially longer than I had planned for but a few individual pieces slowed down the completion quite a bit. Cutting, staining and finishing all the slats was very tedious as each piece received multiple coats of Stain and then multiple additional finish coats of Helmsman Spar Urethane so that it will hold up to the elements. Since you can only do a few sides at a time it makes for a LOT of stop and go. A few of the powdercoated pieces also needed to be re-done and its at least a weeks wait to get anything back each time so it all added up. Thankfully the new owner was extremely understanding and patient with the process and it took a huge weight off of my shoulders.
In terms of what was the most difficult I would have to say the complete cleaning of the cookbox. Even when sandblasting it can be difficult to loosen rock hard debris that's wedged down in the corners of the casting. I made multiple trips back and forth after finding new little specks that drove me crazy ;D The bottom cookbox alone spent at least a couple hours in the blasting cabinet.
The red porcelain lid is also a bit of a chore to get spotless, but it's all worth it in the end [emoji106]
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(http://uploads.tapatalk-cdn.com/20160721/ddf35ed2b8cf15fbcbe0918318eeae64.jpg)
The boneyard [emoji41]
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Love your boneyard, what media did you use for the blasting? In the process of doing my own gasser resto... Will never achieve your level but you have made me want to finish my project..Thanks.
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Wow. I can't believe the time and effort put into that. Ok, so I'm not up with gassers, so what parts out of the donors were you looking for?
Sorry for all the questions, I'm just really taken in by the work. I'll pm you if I have more so not to take up more space.
Great job man. I've looked over this thread like a million times already and don't even own a gas grill. Just the work or craftsmanship alone is amazing.
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Anybody who gives you crap for not putting thought and time into a restoration ought to be tarred, feathered and pissed on.
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That makes me want to sell my 07 Genesis and by an old one to restore. Beautiful work.
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Nice job!
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Matt - that restoration is breathtaking! Thank you for all the pictures - very cool to see the "in process" shots.
Well done,
Winz
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I'd be proud to have that on my porch. Top notch resto bro. Well done
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Matt, that is a tour-de-force ... great work. This "epic" thesis belongs, for all posterity, in the WKC Restoration archive. Please, please, please tell us you'll make it so. NOTE: I truly believe the term epic applies here [emoji10]
SJ
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Agreed - Epic
Also see: unreal, outstanding, stupendous, mother of dragons, and unmatched level of craftsmanship.
(Standing ovation)
- Keep it simple stupid -
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mother of dragons
lmao
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Amazing restore! What powder coat/paint did you use on the internal of the cookbox? I didn't think powder coat did that well with high heat. We have some powder coating contracted out for work and I have thought multiple times about getting a kettle done. Wondering if there is an equivalent to the porcelain coating that can be done at home or by a powder coater.
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Stunning work, as always!
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Wow Matt, great job!
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Thanks everyone for the comments!
What powder coat/paint did you use on the internal of the cookbox?
No paint or powdercoat at all on the inside of the cookbox, it's bare aluminum from the sandblast booth. A garnet media was used.
I didn't think powder coat did that well with high heat. Wondering if there is an equivalent to the porcelain coating that can be done at home or by a powder coater.
You're correct, powdercoat doesn't stand up to the high temps the cookbox would endure so I use a proper high temp paint on the cookbox and cast lid side caps. The frame and shelf brackets etc were all powdercoated. About the only proper way to coat a kettle would be with a Ceramic coating, and its not cheap! It would cost a fair bit more than the kettle itself and you are quite limited on the possible finishes.
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Very Nice Indeed..
8)
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AMAZING!! Well done Matt!
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omg amazing craftsmanship , been restoring things my whole life so can very much understand what you went thru , but you have to admit it's well worth it . picked one of those in green today for free ,but with a side burner . little rusty ,got it for a table for my smoker sj and jj . now I wonder , would I be crossing some weber moral line by doing this ? hope not .
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Beautiful
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That, sir, is bad ass.
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That is simply an awesome transformation. What a great restore.
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Beautiful job, the detail is incredible, this fall will make my first attempt at a full restore on my redhead, you just gave me inspiration.
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@SixZeroFour
do you still have the durawood slats?
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@swamprb I do have some - how many do you need?
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@SixZeroFour Looking for as many as I can get my hands on. Looking for lid handle as well.
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I just completed one of those as well. Decided not to put on the drop shelves. Fabricated a stainless skirt for the front as they sometimes rust. Also did all fasteners in stainless including the casters and axle.
Had RCPlanebuyer do the grates, flavourizors and Z brackets.
Thanks to Brian for the Redwood handle and slats.
Have no idea how to post photos though.
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I just completed one of those as well. Decided not to put on the drop shelves. Fabricated a stainless skirt for the front as they sometimes rust. Also did all fasteners in stainless including the casters and axle.
Had RCPlanebuyer do the grates, flavourizors and Z brackets.
Thanks to Brian for the Redwood handle and slats.
Have no idea how to post photos though.
We definitely need to see pics of this. Here is a good thread explaining how to post pics.
It's fairly straight-forward, and once you do it a few times, it becomes quite easy.
http://weberkettleclub.com/forums/kettle-club-discussions/how-to-post-pictures-here-at-the-wkc/
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@MacEggs what a nightmare.. just went and read the 2 pages how to do it. Then I went and downloaded the photo bucket app to my phone.
Sorry... this should be a drag and drop situation like many of the other forums.
I just wasted 1/2 hour trying to figure this out.
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@Gpinch1 try going to your App Store and searching for the Weber Kettle Club App. You can use the phone app and post pics right from your phone. Very easy.
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@Gpinch1 , there is also the image hosting site operated by the WKC.
http://pics.weberkettleclub.com
Hope everything works out for you. I suggest you start your own thread for these pics of yours.
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@SixZeroFour that turned out beautifully! Great work, as always!
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Been looking at one on gumtree been there for 12 weeks now and getting cheaper(http://uploads.tapatalk-cdn.com/20160828/eb69b7644f86f80e326a3fd999685770.jpg)(http://uploads.tapatalk-cdn.com/20160828/1b5b494d79ebec4d7ab7c3135a942c93.jpg)
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Love the brown. I have not seen any of those.
Would look great with a vintage brown charcoal kettle beside it
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That's a gorgeous red and I love that Brown Genesis! You're right, I don't think Weber did too many chocolate brown Genesis grills. What's the year on that brown one? I'm guessing prior to 1992. '91 was the last year of brown kettles, usually Genesis color availability parallels kettle color but not always.
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Awesome. What stain color on wood did you use? Also did u water resist them or polyurethane coated?
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Awesome. What stain color on wood did you use? Also did u water resist them or polyurethane coated?
Thanks!
I used a stain by SAMAN that's called "Chamois" for this build. The slats then received multiple coats of Helmsman Spar Urethane.
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Wow what beautiful grills . I love all the great photos.
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Wow. Amazing resto. Nice work 604!
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Holy Crap. Incredible. Worthy of a "We're not worthy" comment.
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Looks great, which hi temp paint did you use?