Gasket Replacement Guide

Installation guide for replacing your gasket.


Depending on the amount of cooking you do, you will need to replace your gaskets every few years. Here is a step-by-step guide for installing new gaskets. Click on any of the photos below for an expanded view. Average installation time is 1 hour.

Tools Needed:

maintenance_gasket_01
  • Bristle Brush
  • Paint Scraper
  • Tape Measure
  • Tape
  • Scissors
  • Box Cutter
  • Solvent
  • Gasket Kit
  • Stripper Attachment
  • Electric Drill
  • Shop Vacuum
  • Cloth Rag

1. Remove Old Gasket Material

maintenance_gasket_02

Use a box cutter to make a cross cut on the old gasket material. Pull off the loose material by hand. Alternately, you may be able to pull an area up without cutting the gasket. Remove as much gasket material as possible from the base and dome edges.

2. Remove Remaining Gasket and Adhesive

maintenance_gasket_03

Use a paint scraper with enough pressure to scrape around the edges of the base and dome. Remove as much of the remaining gasket material and adhesive as possible.

Use care not to press too hard or at too steep an angle to avoid chipping or removing the ceramic glaze.

3. Additional Removal (Optional)

maintenance_gasket_04

To remove more of the material or to avoid using a paint scraper, use a 3M Paint & Rust Stripper (model 3M 7772ES) attachment on an electric drill. Use the highest speed with light pressure.

4. Brush the Base and Dome

maintenance_gasket_05

After a few years of cooking, a sooty substance called creosote will build up on the interior of the base and dome. Over time it can become thick enough to flake off onto your food.

Use a soft bristle brush on the interior of the base and dome to remove excess creosote and let it fall into the bottom of the base.

5. Clean the Edges with Solvent

maintenance_gasket_06

Apply solvent to a clean cloth and wipe the edges of the base and dome. This will remove any residual material and dust and provide a clean dry surface to apply the new gaskets.

6. Vacuum the Base

maintenance_gasket_07

Remove any loose material in the base with a shop vacuum. Reinsert the fire box, fire grate and fire ring.

7. Cut the new Gasket Material

maintenance_gasket_08

The ClassicJoe Gasket Replacement Kit includes 14' of material. Use a tape measure and scissors to cut a 2' length for the neck of dome and two 6' pieces for the base and dome.

8. Mark the Center of the Material

maintenance_gasket_09

Place a small piece of tape at the center of the two 6' pieces of the new gasket material. This will help in determining the amount of material left when applying them to the base and dome.

9. Replace the Gasket Material on the Neck

maintenance_gasket_10

Remove the old material by hand. It is OK to leave some of the previous material on the neck. Use the previous steps if desired to remove the old material. Apply the 2' piece of material around the center of the neck and cut, making sure the two ends are flush to each other. This will ensure that the top vent is sealed when cooking or shutting down the grill. Place the top vent on the neck and press down firmly to make sure it fits snuggly.

10. How to Apply the New Gaskets

maintenance_gasket_11

Remove 6-8" of the white backing material. Facing the grill, start the new material on the base at the 12:00 position. Use the inner edge as a guide to ensure that the new material is flush to the interior.

11. Apply New Gasket Material to the Base

maintenance_gasket_12

Apply light tension to the gasket and pull away the backing material as needed. Apply the new material around the diameter of the base. The blue tape indicates that there is enough material to cover the diameter. If the tape is located earlier than the 6:00 position, check that there is enough material to complete the base by laying the remaining material around the base edge. If not, gently lift off the material and reapply.

12. Cut Gasket Material

maintenance_gasket_13

Use a box cutter to remove excess gasket material, so the ends meet flush and create a seamless gasket. Overlapping the material or having a gap will create a leak, which will allow heat to escape and cause that area of the gasket to fail quickly. A gap will allow air to enter, which may reduce the ability to maintain low temperatures and cause longer cooling periods.

13. Apply the Gasket Material to the Dome

maintenance_gasket_14

Use steps 10-12 to apply the new gasket material to the dome. Use the palm of your hand and press down firmly as you work around both of the gaskets. This will ensure that the adhesive backing is mated to the ceramic edges.

14. If a Gap Appears After Applying

maintenance_gasket_15

It is not uncommon for a slight gap (shown in photo) to appear at the front of the grill after the new gasket material has been applied. The gasket material is thick and it will compress and form a seal after heating the grill.

15. Setting the New Gaskets

maintenance_gasket_16

Place half the amount of charcoal normally used for cooking (about 1lb or .5kg). Light the charcoal and close the dome after 5 minutes with the draft door and top vent fully open.

16. Heating and Cooling the Grill

maintenance_gasket_17

Allow the temperature to reach 350°F (175°C), then fully close the draft door and top vent. Press down firmly on the handle a few times to make sure the gaskets mate properly. Do not open the grill until it has completely cooled down. This will allow the adhesive backing on the gasket material to set and bond to the ceramics. A 12 hour period is best. Opening the grill may cause the gasket material to move out of position.

Your Grill is Ready for Cooking

maintenance_gasket_18

The new gaskets are now set and bonded.

Tips:

1. When cooking, use a damp cloth to wipe off any liquids (especially sauces) that drip onto the gaskets. Failure to do so, may cause the gaskets to bond and pull apart if allowed to dry.

2. Avoid flashbacks to extend the life of your gaskets. Learn more about flashbacks on page 18 of the ClassicJoe Owners Manual.