1996 Spirit Drip Tray Rails rusted

Wiess · 08-04-2013, 06:39 AM

The drip tray rails are rusted on my 1996 Redhead Spirit and I am doubtful about getting the bolts out to install new ones. The bolt heads are pretty rusted and do not even take a wrench. My plan is to drill new holes to attach new rails. Any other suggestions?

dwfisk · 08-04-2013, 06:53 AM

Any way you can grind off or drill the old rusty bolt heads then knock them out with a punch? At least that way you could use the existing holes and maybe install new SS bolts & nuts?

beer and bbq · 08-04-2013, 07:57 AM

You might even want to try heating them up with a propane torch to see if they will break free

Wiess · 09-27-2013, 02:42 PM

New rails finally arrived today (on back order and then misplaced at warehouse!!). The old bolts were sprayed several times with penetrating oil while waiting for the shipment to arrive. The bolts would not move with a screw driver or wrench. Then I used Vice Grips, the bolts still did not move but now I have a crack in the housing, one of the four bolt attachment points. Is this cast aluminum? Can it be repaired? Any other thoughts on attaching the rails? The grill works fine and is in pretty good shape other wise. Any help appreciated.

08-04-2013, 06:39 AM	#1
Wiess Found some matches. Join Date: 08-26-11 Location: Torbay, Newfoundland	1996 Spirit Drip Tray Rails rusted The drip tray rails are rusted on my 1996 Redhead Spirit and I am doubtful about getting the bolts out to install new ones. The bolt heads are pretty rusted and do not even take a wrench. My plan is to drill new holes to attach new rails. Any other suggestions?

08-04-2013, 06:53 AM	#2
dwfisk Quintessential Chatty Farker Join Date: 08-01-12 Location: Fairfield, Florida Name/Nickname : Dave	Any way you can grind off or drill the old rusty bolt heads then knock them out with a punch? At least that way you could use the existing holes and maybe install new SS bolts & nuts? __________________ I'm Dave Got a bunch of cooking toys and a custom metal fabrication shop where I spend my time building all sorts of smokers & outdoor cooking gear.

08-04-2013, 07:57 AM	#3
beer and bbq Got Wood. Join Date: 07-05-13 Location: lewiston, ny	You might even want to try heating them up with a propane torch to see if they will break free

09-27-2013, 02:42 PM	#4
Wiess Found some matches. Join Date: 08-26-11 Location: Torbay, Newfoundland	New rails finally arrived today (on back order and then misplaced at warehouse!!). The old bolts were sprayed several times with penetrating oil while waiting for the shipment to arrive. The bolts would not move with a screw driver or wrench. Then I used Vice Grips, the bolts still did not move but now I have a crack in the housing, one of the four bolt attachment points. Is this cast aluminum? Can it be repaired? Any other thoughts on attaching the rails? The grill works fine and is in pretty good shape other wise. Any help appreciated.