A barbecue grill covered in rust not only looks unsightly but can also negatively affect your health and the taste of the food you cook on it. Fortunately, with some time and effort, you can get your rusty barbecue grill looking good as new.

What Causes Rust on a Grill?

Rust occurs when iron materials like the steel used to construct grills are exposed to moisture. The iron reacts with water and oxygen to form rust, which is actually iron oxide. This chemical reaction causes corrosion and wearing away of the metal over time.

There are a few key causes of rust on barbecue grills:

• Exposure to rain, sprinklers, humidity, etc. Anytime the grill gets wet, it can start to rust.
• Storage outside or in a damp area. Grills stored in sheds, garages, or open backyards will have more exposure to moisture.
• Infrequent cleaning. Food, grease, and grime left on the grill retain moisture and encourage corrosion.
• Chipping paint or chrome finishes. Anywhere bare metal is revealed is vulnerable to rusting.
• Salt. Oceanfront areas or even salt in the air can accelerate rusting.

With the right cleaning methods, you can stop new rust from forming and also remove existing rust to extend the life of your barbecue grill.

Dangers of a Rusty Grill

Before we get into all the ways to clean up that crusty rust, it’s worth understanding why it so important to deal with it promptly. Rust isn’t just an eyesore – it can actually be dangerous to use a grill in that condition.

Here are some of the top dangers of using a rusty barbecue:

Flaking Metal: As rust corrodes the grill, eventually pieces will begin flaking off. You don’t want to be cooking food with shards of metal potentially falling onto it.

Weak Structure: Rust seriously compromises the structural integrity of steel and iron. Parts of the grill that are rusted through can be weaker and prone to collapse.

Bacterial Growth: Rust has lots of tiny grooves and openings ideal for trapping food particles and allowing bacteria and mold to grow.

Unhealthy Cooking: Not only can that bacteria contaminate food, but rust can also flake off into what your cooking. Accidentally ingesting rust is not good for you.

Bad Flavor: The tainted smoke from a rusty grill can impart a metallic flavor to meats and veggies. This alters the intended taste.

Now that you know why it’s wise to promptly tend to rust on your grill, let’s explore all the strategies and techniques you can use to clean it up.

Supplies Needed for Removing Rust

Before we dive into the steps for how to clean rust off a grill, you’ll need to gather the right cleaning tools and materials.

Here are the recommended supplies:

• Protective eyewear
• Rubber or latex gloves
• Sturdy wire grill brush
• Putty knife or paint scraper
• Sandpaper (80-100 grit)
• Coarse steel wool pads (000 grade)
• Clean cloths or paper towels
• Bucket of warm water & dish soap
• Vinegar or citrus-based cleaner
• Spray lubricant (WD-40)
• Touch-up paint

For severely rusted grills, you may also need:

• Angle grinder with wire wheel brush
• Chipping hammer
• Metal primer/sealer
• High heat spray paint

Safety should be your top concern when dealing with rust. The protective eyewear keeps debris out of your eyes while working. Gloves guard against sharp edges and chemicals. Try to do cleaning in a well-ventilated outdoor space.

How to Remove Loose Grill Rust

If the rust on your barbecue is still superficial without pits or holes, these techniques can restore the surface.

1. Brush the Cooking Grate

Use a sturdy stainless steel wire grill brush to scrub away any loose rust flakes and caked-on grime from the grate. Apply pressure and rub in the direction of the metal grain.

This helps smooth and flatten the surface to prep for the next steps. Dislodge any large chunks hanging off with a putty knife. Rinse with water and let dry fully.

2. Scrub with Steel Wool

For more stubborn rust spots, take 000 grade steel wool pads and vigorously scour those areas. The coarse woven steel fibers will help abrade off oxidation without damaging the underlying metal.

Dip the steel wool in vinegar or a citrus-based degreaser for extra cleaning power. Rinse the grate thoroughly after scrubbing.

3. Apply Naval Jelly Rust Dissolver

Naval jelly is a specialty phosphoric acid-based solution formulated to convert rust into an inert bluish-black primer. Just brush it onto affected areas, wait 15 minutes, then rinse off. It also leaves a protective coating to retard future rust.

4. Spot Sand Rusted Patches

Use 80-100 grit sandpaper to sand away any remaining stubborn rust spots. Focus on limited areas so you don’t remove too much metal. Wipe with a clean cloth after sanding to clear all residue.

5. Dry Thoroughly

It’s critical that the grate is completely dry before applying any lubricants or paints. Let air dry fully or help speed it up with a heat gun. Moisture under treatments can cause future rust.

6. Apply WD-40

This light oil lubricant can help prevent rust from recurring after removing existing spots. Just spray it over the cleaned cooking surface and allow to dry. Reapply after each grilling session.

With loose surface rust taken care of, the grill should now be ready to safely fire up. But keep an eye on any pits or holes where corrosion penetrated deeper. These weak points will need extra work.

Repairing Severe Grill Rust Pitting

When rust starts eating through the metal and leaving behind cavities and hole, more aggressive cleaning methods are required. Here are some potential solutions:

Grinding with a Wire Wheel

For shallow pits, an angle grinder equipped with a steel wire wheel brush can smooth them out. Wear eye protection and carefully grind across any indented rust spots. Avoid removing more material than necessary.

Hammers and Chisels

Use a small chipping hammer and pointed chisel to chip away badly corroded sections. This works for pits and holes rusted completely through grill components. Striking the chisel carefully knocks away the weakened metal.

Filling with Putty or Fillers

In deeper holes consider filling up the void so food and grease don’t collect there. High-heat epoxies and metal fillers are available for this. Clean out the cavity then apply the filler and allow to fully cure before painting.

Replacing Components

For grill parts like cooking grates or burners that are too far gone, replacement is the best option. Fortunately many manufacturers sell replacement parts to renew common rust prone components. This allows you to save the main frame.

Sandblasting

For extreme cases of rust over large grill surfaces, sandblasting can strip off all the corrosion. This abrades the surface using an air powered nozzle spraying sand at high speeds. Just be careful not to overly pit the metal.

Preventing Rust After Cleaning Grill

Once you’ve put in the hard work to clean up a rusty grill, you want to keep it that way. Here are helpful tips to prevent renewed rusting:

• Paint bare metal: Use high-heat spray paints to coat any exposed iron or steel, like on replacement parts. Match the original color.
• Apply seasoning: Season cast iron grill grates by coating with a thin layer of oil and heating to absorb it. This protects the porous surface.
• Store indoors: Bring the grill inside a shed or garage to protect from rain and moisture when not in use for extended periods.
• Use grill covers: Breathable fabric grill covers protect from weather exposure while allowing ventilation to suppress moisture.
• Keep it clean: Don’t allow grease and food debris to sit too long on a grill after cooking. Stay on top of cleanings.
• Check for damage: Periodically inspect the grill for any new chips, cracks, or peeling metal that could admit water.
• Lubricate: Apply a corrosion inhibitor spray like WD-40 to the grill’s surface after cleanings and before storage.
• Avoid sea salt: If you live near the ocean, try to protect the grill from sea spray and salt-tinged mist which accelerate rust.

With this understanding of what causes rust on grills, how to remove it safely, and tips for prevention, you can keep your barbecue looking and working its best for seasons to come. Don’t let surface oxidation or deep-pitting corrosion take away the joy of outdoor cooking. A well-tended grill is a joy forever!

Tips for Cleaning a Rusty Grill

Removing every last speck of rust from a neglected barbecue grill can seem daunting. But don’t worry – with some elbow grease and the right techniques, you can get that crusty old grill looking fresh. Here are some handy tips for tackling the cleaning job:

Start early in the day – Setting aside a few morning hours will give you plenty of time for the detailed cleaning process without having to rush.

Gather all supplies first – Make sure you have all the necessary brushes, cleaners, gloves, and tools ready to go before starting. Nothing slows you down like having to stop to find something mid-cleaning.

Protect yourself – Wear gloves to avoid cutting hands on sharp metal shards. Goggles keep debris from flying into eyes. A mask prevents inhaling residues.

Work from top down – Detach components like racks and burners to clean individually. Start up top then work down to the bottom and base.

Loosen stuck residue – Allow tough baked-on gunk to soak in hot soapy water to soften before scrubbing. This prevents excessive scratching of the metal.

Clean with grain – Always scrub metal surfaces in the direction of the visible grain. Going against it is more likely to leave deeper scratches.

Rinse thoroughly – Wash away all loosened residue after cleaning a section. Leaving it risks retransferring grime. Check for any greasy film.

Dry right away – Quickly dry all components with a towel or air dryer after washing. Trapped moisture promotes flash rusting.

Deal with holes/pits – Use metal epoxy fillers to plug any corroded-through spots that could harbor bacteria.

Spot prime – Seal cleaned patches with primer before painting so new coats adhere well. Rust resistant primers add extra protection.

Reassemble properly – Carefully reattach parts like burners and racks according to manual instructions after cleaning.

Don’t feel inhibited to call on a grill cleaning professional if the oxidization is especially extensive. Sometimes it pays to bring in the experts! But in many cases, a committed DIY cleaning can restore even a very rusty grill to near new condition.

Step-by-Step Process for Cleaning Rust Off a Grill

Seeing exactly how the experts do it can make tackling a big rust removal project much less intimidating. Here is a step-by-step walkthrough of how to clean rust off a barbecue grill:

Prep Work

1. Gather Supplies – Have wire brushes, sandpaper, cleaning solutions, cloths/gloves, lubricant, primer, and paint ready.

2. Disassemble – Detach cooking grates, flavorizer bars, burners, etc. according to manufacturer instructions.

3. Remove Debris – Use a plastic putty knife to scrape off any loose flakes clinging to surfaces.

4. Soak Components – Mix warm water and dish soap in a bucket and soak smaller parts like grates to loosen gunk.

Deep Cleaning & Rust Removal

5. Scrub Grates – Use a GrillStone brush or 0000 steel wool with a degreaser to scour grates thoroughly.

6. Clean Flavorizer Bars – Dip steel wool in white vinegar and scrub away rust buildup on bars.

7. Brighten Burners – Rub stubborn rust spots on burners with wet 400 grit sandpaper until shiny again.

8. Detail the Lid – Spray lid and interior with naval jelly rust dissolver then scrub with nylon brush.

9. Remove Pitting – Utilize a rotating steel brush on an angle grinder to smooth significant pitted areas.

10. Fix Holes – Fill corroded through spots with high heat epoxy filler and let fully cure before sanding smooth.

Renewing Exterior Surfaces

11. Wash Frame – Use soapy water and scouring pad to clean the outer grill housing and side tables.

12. Spot Prime – Brush metal primer onto any bare metal spots and let dry completely.

13. Spray Paint – Apply 2-3 thin coats of appliance enamel spray paint matched to original grill color.

14. Replace Parts – For sections too damaged, like fireboxes, install new replacement parts as needed.

15. Reassemble Grill – Once all components are cleaned and treated, carefully reattach per manual instructions.

16. Season Grates – Using cooking oil, lightly season cast iron grates by heating on grill after reassembly.

With patience and the right systematic approach, even grills with heavy rust damage can be restored to like-new condition. Just make sure to keep on top of regular maintenance to prevent a repeat!

Home Remedies for Cleaning Rust Off Grills

Commercial cleaners and tools certainly make grill rust removal easier, but you can also get the job done with common household items. When tackling a rusty barbecue restoration, consider these homemade alternatives:

Baking Soda – The abrasive texture of baking soda allows it to scour rust away. Make a thick paste with water and apply to affected areas. Let sit before scrubbing.

Aluminum Foil – For light surface rust, ball up sheets of foil and rub vigorously to abrade it off while also polishing the metal.

White Vinegar – The acetic acid in vinegar dissolves rust. Soak paper towels and let sit on rust spots for 30 minutes before scrubbing.

Lemon Juice – Like vinegar, the citric acid in lemon juice breaks down rust. Slice a lemon in half and directly rub over affected areas.

Onions – Believe it or not, onions have compounds that react with rust to help lift it off metal. Try rubbing onion slices over rust then rinsing.

Molasses – The sucrose sugar in molasses reacts with rust to convert it into a removable coating. Spread it on thickly and let sit for 1-2 hours.

Pantyhose – For light rust, tie a section of pantyhose around a grill brush to help add extra scouring power as you scrub surfaces.

Aluminum Pan – Fill a disposable foil pan with a 50/50 mix of white vinegar and water. Submerge small grill parts to soak and loosen rust.

Steel Wool – Grade 0000 or 000 steel wool pads can scrub away rust without damaging seasoning on cast iron grates like wire brushes might.

Potato – A raw potato rubbed over rust can help lift corrosion and also polish metal. The starch in potatoes helps scour.

Don’t feel limited to commercial kits and branded products. Look around the pantry and cleaning closet for handy items that can often do the job just as well! With some creative thinking, you can remove grill rust without harsh chemicals.

Q&A About Cleaning Rust Off Grills

Still have some questions lingering about the best ways to restore a rusty grill? Here are answers to some of the most frequently asked questions:

Should I keep cooking on a rusty grill while cleaning it?

No, don’t use a grill until all rust is fully removed, including from cooking grates. Rust flakes could keep contaminating food.

Can I leave components soaking overnight?

Yes, letting parts soak for prolonged periods in a rust removal solution allows more time to penetrate and lift corrosion.

How often should I reseason cast iron grates after cleaning?

Plan to reseason 2-3 times per year by lightly oiling grates and running through heat cycles on the grill.

What kind of brush is best for grill cleaning?

Look for sturdy stainless steel bristle brushes with sufficient stiffness to scour. Change brushes regularly to avoid spreading contamination.

How do I clean rust from the grill’s outer body?

Use a degreasing agent, scrub with a non-abrasive scouring sponge, spot prime any bare metal, and spray paint with high-heat enamel.

When should I replace rather than repair a part?

If corrosion has caused holes, deep pits, or structural weakness in a component, replacement is usually safer than patching it up.

How do I dispose of rust debris safely?

Sweep all loose flakes into a bag, seal it, and dispose with regular household waste. Avoid breathing particles.

What areas rust fastest on a grill?

Cooking grates, flavorizer bars, and burner covers see the most direct heat and exposure to grease so rust quickest.

Give that crusty old grill some TLC and you can have it looking factory-fresh once again! With the right techniques and regular upkeep, grills can be kept going strong for many years of cookouts.

Conclusion

Don’t resign yourself to cooking on a rusty grill simply because restoring it seems like too big a headache. With some planning and effort, you can totally transform even the crustiest barbecue workhorse back to its former glory.

The key steps are disassembling components, thoroughly cleaning each piece with the appropriate tools, removing pitted corrosion, properly priming and prepping surfaces, then reassembling the renewed grill.

It also helps to identify causes of rust like moisture exposure or inadequate cleaning practices and take measures to prevent