How To Fix Hole In Bottom Of Charcoal Grill [6 Easy Steps]

If you’ve ever had a charcoal grill, you know that eventually there will be a hole in the bottom of it. And if the bottom of grill rusted out, this can be annoying and lead to problems with your grill, but there is a way to fix it! In this blog post, I’ll show you how to fix hole in bottom of charcoal grill and keep your grill running like new. Keep reading for all the details.

The materials you would be needing to fix your grill are mentioned below:

Wire mesh

Metal sheeting

Silicon caulk




Measuring tape

how to fix hole in bottom of charcoal grill

How To Fix Hole In Bottom Of Charcoal Grill:

Make sure that you have arranged all the above material, now follow these simple steps to follow in order to how to fix rusted grill bottom.

Step 1: Clean The Grill

A clean grill will give you a clear picture of how much your grill is damaged. In case it is not clean, clean it with the help of a wire brush and remove all leftover pieces of food and debris from it.

why does the bottom of my grill rust out

Step 2: Measure The Hole

After cleaning the grill, look closely at the hole, is it small or large? Using a measuring tape, accurately measure the size of hole in the bottom of charcoal grill. By doing this, you will determine what size of wire mesh and metal sheeting you need to cover it.

If the hole is very small, it can be easily fixed with some high-temperature caulk.

Step 3: Cut The Wire Mesh And Metal Sheet To Fit

Once you have the measurements, cut a piece of wire mesh and metal sheeting that is slightly larger than the hole. Then use pair of pliers to bend the corners of the metals. Make sure that these two pieces fit inside and outside of your grill respectively.

Step 4: Attach The Wire Mesh And Sheet To Grill With Epoxy Glue

Apply high-temperature silicon caulk on both pieces (wire mesh and metal sheet). Place them over the hole in your grill with the wire mesh facing up inside and the metal sheeting facing down outside.

Step 5: Secure The Mesh With Screws

Using a drill, screw the wire mesh and sheeting together to make sure they are securely attached.

Step 6: Hammer Down the Edges Of the Sheet

Use a hammer to gently knock down the edges of your sheet so that it is flush with the bottom of your grill.

Once you have followed all these steps correctly, your charcoal grill will be as good as new! Congratulations on fixing your hole!

That’s it! Now you know how to fix a hole in the bottom of your charcoal grill. With this helpful guide, you can easily repair any issues that may arise with your grill without having to buy a new one.

How To Prevent a Whole From Forming In The Grill:

Make a habit of cleaning your grill after every use. Prevent it from rust. If you find any traces of rust, remove it immediately and then apply silicon caulk

Aside from patching or replacing the hole in a charcoal grill grate, there are several other options to repair it without needing to replace it entirely.

One way is to use high-temperature adhesive tape as a temporary solution. This type of tape has strong adhesion and heat resistance that makes it suitable for grilling applications. To use this method, simply take a piece of tape and place over the hole. Press it down firmly so that it adheres properly.

Another option is to use a thin wire mesh to cover the hole. Cut a piece of wire mesh slightly larger than the size of the hole and then attach it using stainless steel screws and washers. This will provide a more permanent fix and can also help keep small pieces of food from falling through the hole.

Finally, some people opt to replace the entire grate with a new one made of more durable material such as stainless steel or cast iron. This is no doubt an expensive option but it could also last significantly longer.

bottom of smoker rusted out

How Do You Clean Rust Off Of A Grill?

Rust can spread quickly and weaken the structure of your grill, leading to potential hazards such as fuel leaks, flames shooting out of the grill, and other dangerous scenarios.

What you need to do is inspect the grill for any rust spots or weak areas. If you find any rusted spot, apply rust-resistant paint or coating on the affected area. This will help prevent the spread of rust and create an extra layer of protection against the elements. If you don’t have any rust-resistant paint or coating, you can also try sealing the area with a sealant or tar-based product.

Once the affected areas are sealed, it is important to keep your grill clean and dry to prevent future rusting. Clean the grill regularly with a wire brush and warm soapy water to remove any food particles, dirt or debris. Make sure to dry it thoroughly afterward so that moisture doesn’t seep into the metal and cause further rusting.


I fixed my BBQ grill using the same method. If you face the same issue, having a small hole in your charcoal grill, I will suggest you to fix it with high-temperature silicone caulk. For larger holes, you need to follow the method of patching up the piece of sheet metal. These simple steps allow you to keep your grill in good shape for years to come!

To get more knowledge about grills and smokers, you may check out more blogs on my website.

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Can I line the bottom of my grill with foil?

The answer to this question depends on what type of grill you have. If you have a charcoal grill, lining the bottom with aluminum foil is not recommended because it can cause dangerous flare-ups due to dripping fat and grease. On gas grills, however, it is generally safe to line the bottom with foil as long as there are no holes or tears in the foil. It can help reduce the amount of cleaning required after you’ve used your grill and prevent small food particles from falling through the grate. Just make sure to replace the foil regularly so it doesn’t become too hot and cause any damage. Additionally, it’s important not to block off any of the air vents on the bottom of your grill, as this can interfere with the flow of air and affect your cooking temperature.

Well, some manufacturers may recommend against lining the bottom of a grill with foil, so it’s best to check your owner’s manual or contact customer service before attempting to do so.

What is the best way to clean a grill grate?

The best way to clean a grill grate is to first make sure that the grill is completely cool. Then, using a wire brush, scrape off as much of the stuck-on food particles from the grate as possible. For extra stubborn bits, use a mixture of equal parts white vinegar and water and scrub with the wire brush. After scraping, use a damp cloth to wipe the grate clean. To remove strong odors from the grill, fill a bowl with white vinegar and place it on top of the hot grates for 10 minutes. Once done, scrub off any remaining residue with soapy water and rinse with a garden hose. For extra protection against rust, apply cooking oil to the grill grates before cooking. This will make the grate easier to clean, and also prevent it from rusting over time. Following these cleaning tips should help keep your grill in top condition for years.

Can I use JB Weld on a grill?

It is recommended to use a high-temperature paint or grill primer on the surface before applying the JB Weld. This will help ensure that the JB Weld will stick and remain durable. Additionally, it is important to ensure that the surface you are applying JB Weld to is clean and free of debris. If there are any particles on the grill surface, they can prevent the adhesive from properly bonding with the material.

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