--- title: "Grill Burners Rusted Through: Holes, Gaps and Ragged Flames: Causes and Fixes" description: "Grill burners rusted through show as ports widened into slots, holes along the tube, flame jetting sideways from a gap, or flakes of rust falling into the tray." url: "https://bbqgrillrepair.center/problems/grill-burners-rusted-through/" --- # Grill Burners Rusted Through: Holes, Gaps and Ragged Flames Grill burners rusted through show as ports widened into slots, holes along the tube, flame jetting sideways from a gap, or flakes of rust falling into the tray. ## What it usually means. A burner lives a hard life: heated to several hundred degrees, cooled by rain, coated with fat and acid from marinades and, on the coast, dusted with salt. Stainless steel holds out for years, cast iron and plain steel for fewer, and even a good burner rusts from the inside once grease and moisture sit in the tube. The damage shows first as ports that grow larger and uneven, then as flakes and pits, then as holes where gas escapes in a jet instead of a neat ring of small flames. A burner in that state heats unevenly, flares at the holes and can roll flame where it does not belong. Habits speed it along: a cover put on over a wet grill, grease never burned off after cooking, a grill parked in the path of a sprinkler or beside a pool, and cleaning by pouring water over the burners. Burners are a normal wear part; most makers sell them by model number, and new burners are often the single change that brings an older grill back to life. The 6 causes, cheapest first Answer these first 01 Are there holes or slots along a burner, or rust flakes in the tray? 02 Do flames jet sideways from a gap instead of burning in a tidy row? 03 Is the grill near the coast, a pool or a sprinkler, and is it kept under a cover? 04 Are the burners stainless, cast iron or plain steel, and how old are they? 05 Are the heat shields and grates rusting too? ## Check these before you book. Grill burners rusted through: 5 checks, and none of them costs anything. 01 Once cold, lift the grates and shields and look along each burner for holes, slots and flakes. 02 Light the grill and watch through the grates for flame jetting from the side of a burner. 03 Stop using any burner with a hole that throws flame sideways, and book. ### Also worth checking - Find the model number on the data plate so the right burners can be ordered. - Let the grill cool and dry before covering it, and burn off grease on high for a few minutes after each cook. ### How soon does it need a visit? Rusted burners are not an emergency, but they get worse with every cook. Stop using a burner that jets flame from a hole, and book a replacement visit. ## The causes, cheapest first. 6 things grill burners rusted through: holes, gaps and ragged flames turns out to be, from a cover holding moisture over a warm grill to firebox rusted through along with the burners. [The cost guide](https://bbqgrillrepair.center/cost/) 1. 01 no repair ### A cover holding moisture over a warm grill A cover put on while the grill is still warm and damp, or left on through weeks of rain, keeps a wet mist against the steel. Let the grill cool and dry before covering it. No repair: check it yourself 2. 02 no repair ### Water used to clean the burners Water poured or sprayed over burners sits inside the tubes and rusts them from within. A dry brush on a cold grill is gentler. No repair: check it yourself 3. 03 low ### Shields rusted too, letting fat reach the burners When the shields above fail, fat and marinade drip straight onto the tubes and eat them faster. New shields protect the new burners. [Fixed by grill heat shield and grate replacement](https://bbqgrillrepair.center/services/grill-heat-shield-and-grate-replacement/) 4. 04 moderate ### Salt air near the coast Salt settles in the ports and pits even stainless steel. Burners made for the model are fitted, and a rinse-and-dry routine slows the next round. [Fixed by grill burner replacement](https://bbqgrillrepair.center/services/grill-burner-replacement/) 5. 05 moderate ### Burners at the end of their life After enough seasons every burner thins out. Replacing the full set together keeps the heat even across the grates. [Fixed by grill burner replacement](https://bbqgrillrepair.center/services/grill-burner-replacement/) 6. 06 moderate to highest ### Firebox rusted through along with the burners When the firebox floor and walls are holed as well, the visit weighs a rebuild against a new grill. [Book a diagnostic visit](https://bbqgrillrepair.center/services/diagnostic-visit/) [On a freestanding gas grill](https://bbqgrillrepair.center/types/freestanding-gas-grill-repair/) ## What else it could be. Most often confused with grill uneven heat: hot spots and cold corners on the grates, then grill yellow flame and soot on the grates. [All problems](https://bbqgrillrepair.center/problems/) ### Grill Uneven Heat: Hot Spots and Cold Corners on the Grates 6 causes ### Grill Yellow Flame and Soot on the Grates 5 causes ### Grill Flare-Ups Every Time Food Hits the Grates 6 causes Gas or fire at the grill ### Grill Flashback: Flames Behind the Knobs or Under the Panel 6 causes ## The makes it happens on. 23 makes on this site; grill burners rusted through: holes, gaps and ragged flames can show up on any of them. Each mark opens that make's own page. [All 23 brands](https://bbqgrillrepair.center/brands/) ## Grill Burners Rusted Through: Holes, Gaps and Ragged Flames, where we come out. 9 metros, each with its own page. 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It varies widely with the metal, the climate and the care. Stainless burners on a covered, cleaned grill can last many seasons; plain steel near the sea may need replacing within a few. ### Can a small hole in a grill burner be patched? No. A patch will not hold at burner heat and changes how the gas flows, so the burner is replaced. ### Are universal replacement burners a good idea? They may match the length but not the port layout or the alignment with the orifice, which affects flame and heat. A burner made for the model number is the safer choice. ### Does a stainless BBQ still rust near the ocean? Yes. Salt spray stains and pits even good stainless steel. A fresh-water rinse when cool, a dry cloth and a cover once dry all slow it down. --- **[Read on the site: Grill Burners Rusted Through: Holes, Gaps and Ragged Flames: Causes and Fixes](https://bbqgrillrepair.center/problems/grill-burners-rusted-through/)** **[Book a visit with BBQGrillRepair.center](https://bbqgrillrepair.center/schedule/)**