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:
![](https://dl.dropbox.com/s/r784ipcsphrpss0/IMG_0046.jpg?dl=0)
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:
![](https://dl.dropbox.com/s/umder31gdtjz2u0/IMG_0047.jpg?dl=0)
You can see how much longer the new tubes are compared to the Genesis JR:
![](https://dl.dropbox.com/s/q31qzkg9k1zurin/IMG_0048.jpg?dl=0)
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.
![](https://dl.dropbox.com/s/yf19ljuscnmwy5b/IMG_0049.jpg?dl=0)
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.
![](https://dl.dropbox.com/s/0o8s15yg8nhr39a/IMG_0055.jpg?dl=0)
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.
![](https://dl.dropbox.com/s/6cncqezxz4qty82/IMG_0056.jpg?dl=0)
![](https://dl.dropbox.com/s/zuqb3cuqup7d3uf/IMG_0060.jpg?dl=0)
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
![](https://dl.dropbox.com/s/y9br1xz1ko88s5j/IMG_0061.jpg?dl=0)
Rather than notching the end, I simply drilled a hole to fit the screw that holds the burner tube in place.
![](https://dl.dropbox.com/s/ywe0terczj53typ/IMG_0062.jpg?dl=0)
There you have it. Nice blue flames and a set of burner tubes that should last for quite a while.
![](https://dl.dropbox.com/s/tpwx075qoaumjen/IMG_0065.jpg?dl=0)
Had to top it off with some new flavorizers
![](https://dl.dropbox.com/s/q2s90sxb7zu69xi/IMG_0068.jpg?dl=0)
Project is coming along nicely!
![](https://dl.dropbox.com/s/lx3nu75a7ij3g01/IMG_0069.jpg?dl=0)
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