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FlashJim 07-22-2012 01:45 PM

Rebuild Log: $25 Weber Performer CL Find (Lots of pics)
I hope this rebuild log helps someone with their rebuild or at least gives them an idea what to expect with a used Weber from Craigslist.

I had been searching on Craigslist for a while for a Weber Kettle of some sort. I actually gave up and bought a OTG from HD. When I got home, I sat down and thought I'd look on CL one last time. I stumbled across an ad for a "Weber Grill - $25". I quickly emailed them and asked for pictures.

Photo from the CL ad:

Needless to say, I had the grill at my house within an hour. I had just bought myself a 2009 Weber Performer with Touch-N-Go Gas Assist! Ok, so the handle on the lid was pushed in, it had no front casters and no bottom rack. But it was cheap. :becky:

Time to evaluate what I actually bought.

The cooking grate has to go, but the charcoal grate is fine.

The center of the lid is pushed in.

What looks like peeling paint underneath the lid, isn't. It cleans off.

Top view of the Performer.

The ash catcher had rock hard ash that was stuck to the metal.

The "Gas Assist" burner was actually in good shape.

FlashJim 07-22-2012 01:54 PM

Let's clean this sucker up and rebuild it!

I started the rebuild by removing the table.

With the table out of the way, you can access the burner assembly.

This shows how the wires connect to the burner tube.

I used a 1/2" socket and a screwdriver to remove the burner assembly from the kettle.

With the two bolts removed, the burner assembly slides right out.

Close up view of the hose/burner connection that's held together with a retainer clip.

Use pliers to remove the clip and the hose can be pulled out of the end of the burner tube.

Next I unscrewed the igniter from the burner tube.

Now it's time to remove the spark generator and regulator from the front panel.

After unplugging the wires, remove the nut to remove the spark generator.

You'll need a 1/4" socket to remove the regulator. I left the hose connected so I didn't have to
reseal the connection.

The knob slips through the front panel, so there's no need to remove it.

FlashJim 07-22-2012 01:56 PM

The next thing to remove is the tool holder. It's held on by four 1/2" nuts.

The control panel door is held on by two 1/2" nuts and two tabs.

Four bolts are removed to allow the kettle bowl to be lifted out.

Lift the front and rear panels straight up to remove them.

I dropped the kettle bowl back into the frame to make it easier to clean.

A 1/2" socket is used to remove three nuts that fasten the lid holder to the bowl.

The ash catcher ring is removed by releasing the three tabs behind each leg stub on the kettle bowl.

FlashJim 07-22-2012 02:00 PM

Now that most of the grill is dismantled, it's time to start cleaning and repairing.

Standard off the shelf Easy-Off was used to clean the bowl and lid. The after photo is after letting the Easy-Off do it's work for 20 minutes.

I used a citrus based cleaner on the entire grill after I rinsed the Easy-Off off. Now that it's all shiny and clean, it's time to fix everything that's broken and reassemble. The correct casters for the 2009 Performer is Weber part # 68238. The inserts are round.

The original insert had seen better days. It looks like the grill lost it's casters a long time ago.

To replace the insert, use pliers to twist and pull it out of the leg. Not much force is needed. Chances are it can be done by hand.

This is definitely the correct replacement part. The new insert just pops right in.

The replacement caster clicks in with little effort.

The next thing to address is the bent front frame. It appears that something heavy hit the lid and table.

I measured the rear frame and bent the front to match. Adjustments were easy because the frame is easily bent.

FlashJim 07-22-2012 02:06 PM

The replacement bottom rack arrived bubble wrapped and is painted black for this year Performer.

To install the rack, the side panel is removed.

One end of the rack is slipped into the side panel and pushed in as far as it can go. The remaining side panel is reinstalled after the rack is slipped into it.

The frame is straight and the rack and casters are installed.

Slide the front and rear panels down onto the frame rails to reinstall.

With the panels in place, the bowl can be bolted to the frame.

The burner was cleaned up in less than a minute with nothing but sandpaper.

The igniter is screwed into the burner and the assembly is reinstalled and bolted to the bowl.

The regulator and igniter button are reinstalled and the wires are reconnected. The connectors are unique and there is only one way to plug everything in.

The tool holder, gas assist door, charcoal bin and table are reinstalled. The grill is almost done!

mwmac 07-22-2012 02:08 PM

Very cool. Looking forward to seeing your finished Performer on its first cook!

FlashJim 07-22-2012 02:08 PM

I chose to keep the original charcoal grate. It was rock solid.

The original grate was in bad shape so I opted to buy new. I felt this was a good time to try out one of the cast iron grates on the market. The cheapest cast iron grate for the 22.5"/18.5" Weber Kettle is the replacement unit from Char-Broil. This is a two piece unit and I bought it from Academy, Part #: 7315453, SKU #: 0021633896

The last remaining parts to reinstall is the ash catcher assembly.

The grill is complete! Beginning to end the rebuild/cleanup only took about two hours.

I found a spare Coleman propane cylinder and screwed it in place. The grill fired right up with the first attempt.

Bebe 07-22-2012 02:11 PM

... and i've thought i'm the only nut (according to my wife)!

excellent job!!!

FlashJim 07-22-2012 02:15 PM


Originally Posted by Bebe (Post 2145313)
... and i've thought i'm the only nut (according to my wife)!

excellent job!!!


Yeah, my wife knows to step aside when I pull out the tool box and camera. :becky:

charrederhead 07-22-2012 02:21 PM

Well done! :clap2:

You have motivated (shamed) me to finish cleaning up mine.

bbqchicken 07-22-2012 02:27 PM

great work! now get her dirty :thumb:

jaronimo 07-22-2012 02:27 PM

looks good!

I want details about that cast iron kettle grate. I have been kicking around getting one. let me know how it works for you.

FlashJim 07-22-2012 02:36 PM


Originally Posted by jaronimo (Post 2145337)
looks good!

I want details about that cast iron kettle grate. I have been kicking around getting one. let me know how it works for you.

Let me get a few more uses out of it and I might start another thread for it. I've used it twice and I love it. My friend just bought the Gourmet system and just judging by the pics he sent me, you can't go wrong with that option.

With my grate, adding coals after the center grate in place is a pain. I'll figure it out. I haven't needed to yet, but I like the option.

Fishawn 07-22-2012 03:01 PM

Great post. I have the exact same Performer (not as clean though ha ha)

caseydog 07-22-2012 03:25 PM

What was the final cost when you were done?


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