Okay first of all, I am not an expert with Natural Gas Grills, nor do I claim to be one. If you aren’t comfortable working with gas… don’t try to do this on your own. Also, you will likely HAVE to do some minor modifications to your grill, hence voiding any warranty that you might still have. Keep this in mind. Another thing that you have to know is that this is just a GUIDE; I will be in NO way responsible for ANY damages to you, your family, or your property if this doesn’t work for you. If you attempt this project, you do so at your own risk. Now that we’ve covered all that, let’s move on to the fun stuff.
First thing we do is inspect the grill you currently have, before we convert it to natural gas we want to be sure it’s worth it. Check the burner, is it rusted or burnt out? Are the cooking surfaces in good condition? Is the case rusting? Does the igniter still work properly? If you’ve said no to any of these you may want to consider buying a new grill all together.
In general natural gas grills are very large, and you’ll be hard pressed to find one under 300 bucks, so if you don’t want a huge grill and you don’t want to dish out that much money for one, go ahead and spend the 100 or so on a new propane grill and continue the conversion process.
Next you have to decide where to tee into the gas line. Do yourself a favor and do not tee in at the meter. Once you’ve decided where you want it, shut the gas off, and install the tee wherever you want it, for safety sake install a tee with a shut-off. When you’re putting this all together be sure to use a sealant on ALL pipes that is approved for use with gas… Gas leaks are bad.
Run whatever piping you’ve chosen out to where you are going to have your grill sitting, and install another shut-off at that end. In my project I ran ½” flexible gas line under the house, and ½” rigid black pipe through the skirting and anywhere outside. The flexible line is more expensive but you’ll thank yourself later for getting it.
Now, turn the shut-off at the far end (where your grill will sit) off and turn the gas back on, check EVERY connection for leaks, this can be easily done with a bit of soapy water, or just spraying Windex on it. If you see bubbles, its leaking and you’ll want to turn the gas off right away to get it fixed. Once you’ve got all that checked, and any leaks that were found got fixed, go through and relight all the gas appliances in your house.
Converting your grill.
First remove the regulator. The regulator was there to regulate the pressure of the propane, it is no longer needed, and the regulator on your house will control the pressure to the grill. Locate the regulator and follow the hose back to the grill. If you have a side burner you may come to a tee with one hose going to the main and the other going to the side burner, either unscrew the ends or cut the hose a few inches below the tee or burner. If your line is crimped you have no choice but to cut it.
Next you will need to make the orifices slightly larger. The orifices are found in the control knob assembly. The control knob assembly simply slips inside the two tubs sticking out of the burner. Depending on your grill, the easiest way is probably to just remove the entire front panel, shouldn’t be too difficult, likely just a couple of screws. The reason for making the holes larger is because natural gas doesn’t burn as hot as propane, so it takes more natural gas to make the grill as hot as it needs to be, by making the holes larger you are letting more gas into the burner, and therefore making more heat.
Now we drill out the orifices, on most grills the orifice on each knob has two holes; the larger of the two should be fine so you’ll only need to drill out the one. With the orifices now exposed, drill them out slightly bigger, a 1/16” inch drill bit would suffice. Be VERY careful when you do this, if you screw up, or make the holes to big, you have to get a new set of orifices and start over. So don’t rush yourself and do this right the first time.
The last step is to connect the grill to gas. I used a long black rubber gas line, not the cheapest alternative, but very weather resistant, will last a very long time. Screw one end into the shut-off of the gas line, and the other end into the grill. If you had to cut the line insert a barbed fitting into the hose and secure with a hose clamp. Most grills will need a 5/16” barbed fitting, but just to be safe double check, most of the time the size is printed right on the hose.
Turn on the gas to your grill and check the two new connections for leaks, if everything is as it should be go make your family some burgers and enjoy your new natural gas grill. You may noticed that the flame doesn’t get enough air when the lid is shut all the way, if that is the case modify your grill to leave the lid open about an inch and that should fix the problem.
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