How to Clean a Rusted BBQ Grill - Outdoor Cabinets

Cleaning a rusty BBQ grill can seem like a daunting task, but with the right tools and techniques, you can have it looking brand new again. A well-maintained grill not only looks better, but it will also cook more evenly and last longer. Here’s an in-depth guide on how to clean a rusted BBQ grill.

Assess the Level of Rust

Before deciding on a cleaning method, take a close look at the grill to determine how much rust there is. Light surface rust can often be removed with a good scrubbing, while thicker rust deposits or flaking/peeling rust may require more heavy-duty cleaning.

Is it just surface discoloration or does the rust penetrate deep into the metal?
Are there any visible pits, cracks, or holes caused by the rust?
How much of the grill surface is covered in rust? Isolated spots or widespread rust?

Answering these questions will help you gauge the severity of the rust and decide if DIY cleaning is possible or if you need a professional restoration service.

Gather the Right Supplies

Cleaning a rusty grill requires having the right tools on hand. Here are some must-have supplies:

Protective gear – Gloves, eye protection, mask/respirator if using chemical rust removers
Cleaners/degreasers – Citrus or vinegar-based products work well
Abrasives – Wire grill brush, steel wool (fine to coarse grade), sandpaper
Rust removal solutions – Naval jelly, phosphoric acid, vinegar, or commercial rust removers
Scrubbing pads/sponges – Both soft and abrasive types come in handy
Drop cloths – To protect nearby surfaces from drips and debris
Garbage bags – For proper disposal of rust flakes and residue

Gather all supplies and put on protective gear before starting to scrub the grill.

Remove Loose Debris and Grease

Before attacking the rust, do a preliminary cleaning to remove built-up grime:

With grill grates removed, use a hose to spray away any loose dirt or debris inside the grill body.
Use a degreasing solution and a stiff scrub brush to remove caked-on grease and food residue. Apply degreaser and let it soak 5-10 minutes before scrubbing.
Vacuum out debris from the bottom and underside of the grill. Pay special attention to venturi tubes and any hidden crevices.

Thoroughly removing grease and grime will allow your rust removal efforts to be more effective.

Treat Surface Rust with Abrasives

For light surface rust that hasn’t damaged the metal underneath, abrasives like steel wool, wire brushes, and sandpaper can remove rust and restore the grill’s shine.

Start with fine grade steel wool or fine to medium sandpaper. Rub the abrasive back and forth over rust spots.
Use a wire grill brush to scrub rust from grill grates. Replace brush if bristles start falling out.
For stubborn spots, use progressively coarser abrasives. But be careful not to overly scratch or gouge good metal.
Wipe away all rust residue and reapply abrasives until you’ve removed rust down to bare metal.
Clean with degreaser again when finished.

Use Chemical Rust Removers

For heavy rust that requires more than just scrubbing, applying a chemical rust removal solution can help dissolve and lift rust from metal.

Vinegar – Spray undiluted vinegar and let it sit for an hour before scrubbing.
Naval jelly – Brush jelly onto affected areas, wait 30-60 minutes, then rinse. Reapply as needed.
Phosphoric acid – Wear eye and skin protection when using this harsh acid. Apply with a brush and rinse after 15 minutes.
Commercial rust removers – Spray on and let sit according to package directions before scrubbing and rinsing.
Always have a hose ready to rinse chemicals away after the recommended dwell time.

Use a Grinder to Remove Severe Rust

For BBQ grills with extensive rusting, pitting, or flaking rust, using a power tool like an angle grinder may be necessary:

Fit the grinder with a wire cup brush attachment and adjust to a low speed setting.
Holding grinder firmly, move the wire brush back and forth across rusted areas to strip away rust.
Use a flapping disc attachment to smooth and flatten pitted areas after removing loose rust.
Wear a protective mask, goggles, gloves, and ear protection when using a grinder.
Avoid overheating one area to prevent damaging the metal – keep the grinder moving.

Sand and Finish the Metal

Once all rust is removed, the last steps are to smooth and polish the metal:

Wipe away any leftover residue and then sand the entire grill using fine sandpaper to smooth everything to a uniform surface.
Sweep, vacuum, or wipe away sanding dust.
Apply a thin coat of high-heat automotive paint if you want to change the grill color. Use masking tape for crisp edges.
To protect from new rust, spray on a clear enamel top coat. Allow time to cure before heating grill.
Consider applying high-temp automotive wax to help condition and preserve the grill surface.

Prevent Rust from Returning

To help keep your grill rust-free after all that cleaning work, be diligent about:

Covering the grill when not in use – invest in a good BBQ grill cover.
Applying vegetable oil or silicone spray to the grate after cleaning.
Storing the grill totally dry – wipe away moisture and allow to air dry.
Routinely brushing/scrubbing the grates after each use.
Applying touch-up paint on any new nicks/scratches.

With proper care and maintenance, you can prevent new rust from taking hold and enjoy many more years of great grilling!

Frequently Asked Questions

Should I paint over rust or remove it first?

It’s always best to thoroughly remove rust first before applying paint. If paint is applied over rust, it will just start bubbling and flaking off as the rust continues to grow underneath it. Get down to bare metal before painting.

What kind of paint should I use on a grill?

High-temperature automotive paints formulated for engine blocks or exhaust systems works best for grills. Look for paint that can withstand temperatures of 500°F or higher.

What’s the best way to remove rust from small crevices?

Use a spiral seamer brush, toothbrush, or cotton swabs to scrub naval jelly, vinegar, or other rust removal agents into small spaces like venturi tubes. Let it sit before scrubbing vigorously to lift rust out of cracks.

Is it safe to use rust removers on cooking surfaces?

Most rust removers should not be used on cooking surfaces like grill grates where food is prepared. Stick to abrasives on cooking surfaces. Only use chemicals inside the body of the grill.

Can I save a grill with extensive rust damage?

It depends on how compromised the metal is. Light surface rust can be removed, but deep pits, holes, and crumbling metal may be beyond repair. If the structural integrity seems compromised, it may be time to replace the entire grill.

Conclusion

Although restoring a rusty BBQ grill requires some elbow grease, the right combination of abrasives, chemicals, power tools, sanding, and repainting can give even a badly rusted grill new life.Regular upkeep and maintenance will help prevent recurring rust so you can enjoy your grill’s second act for many cookouts to come. With patience and persistence, you can tackle a DIY rust removal project and keep that old grill in service.