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Unread 07-11-2008, 11:10 PM   #1
swamprb
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Default ***Big Green Egg Rescue***

Or, I hope this works!

Here are some pics of my Large BGE and the crack that put it out of service, hopefully you won't ever have to do this, but let it serve as something to look out for if it ever comes up.



Wire brushed the interior


Used a Dremel to channel the cracks to fill with JB-Weld




Did the same with the exterior-the glaze is pretty hard!


Coat area with Furnace cement


Add a Rutland gasket




Next onto the firebox!


Channelled out the cracks, filled with JB, then coated with furnace cement, and into the oven at 500* for 5 hours.




The heat caused the JB to bubble under the furnace cement, but it is still very solid, I plan to coat it with another coat and heat it up before I do a charcoal burn.




Ordered some touch up paint for the exterior and coated the entire inner surface with the Rutland cement. I'll update the progress as it goes and hopefully I'll be Eggin' soon!
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Unread 07-12-2008, 12:04 AM   #2
MayDay
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Question How did the BGE crack?

Hi Brian, I hope your JB will survive in the fire box. Mine literally turned into powder after only 4 small charcoal firings. However, I hadn't covered it with furnace cement at the time.

Weird also how the furnace cement bubbled up all over your firebox (not just over the area of the JB). Could it be due to trapped moisture? Are the bubbles solid or just air pockets? How long did you wait for it to dry before baking it in the oven?

OK, the big question: How did you crack your big BGE?
(Thought the ceramic BGEs were tougher and rated higher for heat than the red clay pot Kamados?!)

Hope the rescue goes well. I'll probably get back to my own restore (Project Humpty) next week.
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Unread 07-12-2008, 07:03 AM   #3
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I have the same question, How did the EGG crack?
Is this a common thing. As much as I would like to have and Egg, if this is a common concern I'm not going to spend the money on it. I'm not handy so if I got one and it cracks, it would never get fixed.
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Unread 07-12-2008, 07:19 AM   #4
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Quote:
Originally Posted by BBQ_MAFIA View Post
I have the same question, How did the EGG crack?
Is this a common thing. As much as I would like to have and Egg, if this is a common concern I'm not going to spend the money on it. I'm not handy so if I got one and it cracks, it would never get fixed.
with a new egg purchased from a storefront dealer, there is a lifetime warranty so if any part of the egg cracks from normal use, it will be replaced, no questions asked. that's the risk of buying a used egg with no warranty
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Unread 07-12-2008, 09:57 AM   #5
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Nice job bro...Ol' Betsy may be doomed to a life of Low-n-Slow after all...(not that there's anything wrong with that!)
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Unread 07-12-2008, 11:19 AM   #6
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Quote:
Originally Posted by BBQ_MAFIA View Post
I have the same question, How did the EGG crack?
Is this a common thing. As much as I would like to have and Egg, if this is a common concern I'm not going to spend the money on it. I'm not handy so if I got one and it cracks, it would never get fixed.
Quote:
Originally Posted by Rick's Tropical Delight View Post
with a new egg purchased from a storefront dealer, there is a lifetime warranty so if any part of the egg cracks from normal use, it will be replaced, no questions asked. that's the risk of buying a used egg with no warranty
Thanks for the info.

I'm back on the egg wagon again.
I hppe Mrs. Mafia ia reading.
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Unread 07-12-2008, 04:28 PM   #7
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I just repaired my Imperial Kamado firebox (it's still curing) using nothing but watered down Rutlands Furnace Cement (to a cottage cheese or sour cream consistency) and slathered the entire outer surface and eventually the inner surface.. I put it on pretty thick since I find that too thin a layer can come off in some cases..
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Unread 07-12-2008, 04:36 PM   #8
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Quote:
Originally Posted by osx-addict View Post
I just repaired my Imperial Kamado firebox (it's still curing) using nothing but watered down (to a cottage cheese or sour cream consistency) and slathered the entire outer surface and eventually the inner surface.. I put it on pretty thick since I find that too thin a layer can come off in some cases..
watered down, what?
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Unread 07-12-2008, 04:39 PM   #9
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Quote:
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watered down, what?
Doh.. Rutlands Furnace Cement.. I guess water alone wouldn't do it eh?

Sorry..
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Unread 07-12-2008, 04:43 PM   #10
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Quote:
Originally Posted by osx-addict View Post
Doh.. Rutlands Furnace Cement.. I guess water alone wouldn't do it eh?

Sorry..
Thanks, I was hoping I didn't skip over something important!
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Unread 07-13-2008, 01:29 PM   #11
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I coated the interior of the BGE with Rutland Stove and Gasket cement and it sets up hard. Gonna let it dry out in the hot sun before I fire it up! Added a Rutland stove gasket to the bottom also.



Hope this does the trick! Not Eggin's been killin' me!
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Unread 07-13-2008, 05:12 PM   #12
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Quote:
Originally Posted by swamprb View Post
I coated the interior of the BGE with Rutland Stove and Gasket cement and it sets up hard. Gonna let it dry out in the hot sun before I fire it up! Added a Rutland stove gasket to the bottom also.



Hope this does the trick! Not Eggin's been killin' me!
Looks like a "demo" is in your near future...have you spent your "Bush" money yet...or should I be a little more pc and say "Economic Stimulus Check"...
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Unread 07-22-2008, 04:54 PM   #13
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Default Test Burn failure

FARK!!! This is driving me nutz! I did a test burn on the Egg last night, and most of the furnace cement bubbled up and flaked off the interior of the Egg and outside of the bottom, and the interior of the firebox. The JB-Weld has held up and no sign of it failing-yet! I slow baked the firebox in my oven overnight, the furnace cement on the back is OK. I'm about ready to give it the heave-ho! I've never had any problems with the clay Kamados like I'm having with this BGE repair. I'm dying to cook on it, just want it done right!
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Unread 07-22-2008, 05:08 PM   #14
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That's too bad Brian. It is frustrating putting that much time on something only to have to go back to square one. Your persistence and tenacity will pay off. Hope i never have to do it.

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Unread 07-22-2008, 07:50 PM   #15
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Demo Eggs Include:
  • Large Egg, Egg-Mates (Side Shelves)
  • Egg Nest (Stand)
  • Ash Rake
  • Grill Gripper
  • Approx 1/2 bag of Lump Charcoal.
Retail for this package is $932.20. Your cost is $715, over $200 in savings for this once a year event.

To purchase your Demo Egg, please visit your local Eggfest Sponsor to pre-pay for the Egg.
You will need to pick the Egg up at the Pacific Northwest Eggfest between 4:30 and 5:30 p.m.
You must register for the Eggfest in order to purchase a Demo Egg. The Egg may still be warm, so plan accordingly.

We will also have plate setters that have been used one time with the Demo Egg available for $35 each. (You save over $10)

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