You can replace your grill handle with just a few simple steps. This is a quick and easy process that works for most people who enjoy DIY projects. Grab your tools before you get started. Some grills use rivets or need extra steps when you install a replacement grill handle.
Key Takeaways
Get all the tools you need first. You will need a screwdriver, drill, and a new handle. Having tools ready helps you work faster and easier.
Take off the old handle slowly. Use the correct tools and do not rush. This helps you not break the grill. Put the screws in one place so you do not lose them.
Put on the new handle tightly. Make sure it fits and does not move. Check the handle often before you grill to stay safe.
Replacement Grill Handle: Tools and Prep
Gather Tools and Materials
Before you start, make sure you have everything you need for your replacement grill handle project. Most grills use simple fasteners, but some may have rivets. Check your grill to see if the handle is screwed on or riveted. This will help you pick the right tools.
Here’s a handy list of tools you might need:
Screwdriver (Phillips or flathead, depending on your grill)
Harbor Freight Pittsburgh socket set
Harbor Freight ratchet
Knipex pliers
Drill (for rivets)
Cut-off tool (if you need to remove stubborn parts)
Screws or bolts (if your new handle does not come with them)
You can find a replacement grill handle online from trusted sources. Here are two popular options:
Source | Features | Link |
|---|---|---|
Offers a variety of grill parts, including handles, searchable by brand or model number. | ||
Provides a wide selection of grill parts and accessories, with expert assistance available. |
If you want extra peace of mind, some brands offer warranties for your replacement grill handle. Char-Griller gives you a 5-year burn and rust-through warranty, but it does not cover scratches or dents. Monument Grills lets you apply for warranty service if you have problems with your replacement grill handle.
Safety Tips
Always work on a cool grill. Hot surfaces can burn you. Wear gloves to protect your hands, especially if you need to drill out rivets or use a cut-off tool. Keep your tools organized so you do not lose any screws or parts. If you feel unsure about any step, ask a friend for help or check your grill’s manual. Taking your time will help you install your replacement grill handle safely and correctly.
Replace the Handle: Step by Step
Remove Old Handle
Start by making sure your grill is cool and safe to touch. You want to remove the old handle before you can set up the new handle. Most grills use screws to hold the handle in place. Grab your screwdriver or socket set and turn each screw counterclockwise. Place the screws in a small container so you do not lose them. If your grill has a handle bracket, check for extra screws or bolts that might hold it tight.
Some grills, like the big green egg handle, may use different fasteners. Look closely at the ends of the handle bracket. If you see rivets instead of screws, you will need a different approach. Do not rush this part. Take your time and make sure you do not damage the grill lid or the handle bracket.
Address Rivets or Broken Inserts
If you find rivets holding the handle or handle bracket, you need to drill them out. Here’s a safe way to do it:
Tip: Use an angle grinder to cut off the rivet head. Smooth the area with a flap wheel. Mark the center of the rivet with a punch. Drill out the rest using a 1/2″ drill bit. This method works fast and usually takes about five minutes per rivet.
Sometimes, the inserts inside the grill lid break or strip. If this happens, you can replace the thread inserts or use longer screws to reach deeper into the metal. For a big green egg handle, check if the inserts are still strong. If not, swap them out before you install the new handle. Swapping out your handle is easier when you fix these problems first.
Install Replacement Grill Handle
Now you are ready to install the new handle. Line up the handle bracket with the holes on your grill lid. Hold the new handle in place and start screwing the new handle to the grill. Use the right screws for your grill. Here are some common screw types that work well for grill handles:
Screw Type | Part Number | Price |
|---|---|---|
86915 | $6.12 | |
Screw – #6/32 X 1/4 Inch | 4786985 | $7.33 |
Screw, 8-32×5/16, Combination | 86448 | $7.33 |
Screw, Stainless Steel, 10-32 | 97613 | $7.33 |
If you have a big green egg handle, make sure you use stainless steel screws. These resist rust and last longer. Some grills need special handles. Here are a few examples of replacement grill handles that fit popular brands:
Grill Brand | Model Numbers |
|---|---|
720 0789H 2020 US, 720 0789H 2021 US, 720 0789M 2021 US, 720 0789MB 2021 US, 720 0830HA 2021 CA, 720 0830HA 2021 US, 720 0968 2019 US | |
Bull BBQ | 38″ Grill part # 57007 for Urban Island or Bullet brand Vertical door, door/drawer combo, double door, tank drawer and double drawer only |
Hold the new handle steady as you tighten each screw. If your grill uses a handle bracket, make sure it sits flat against the lid. Do not overtighten the screws. You want the new handle to feel snug but not crush the bracket or the lid.
Secure and Test Handle
After screwing the new handle in place, give it a gentle tug. The handle should not wiggle or move. If you feel any looseness, check the screws and tighten them a bit more. For grills with a handle bracket, make sure both sides are even and secure.
Test the new handle by opening and closing the grill lid a few times. The big green egg handle should feel sturdy and comfortable in your hand. If you notice any issues, double-check the screws and the handle bracket. Swapping out your handle is complete when everything feels solid.
Note: Always check your new handle before every grilling session. A loose handle can be dangerous. Regular checks help keep your grill safe and easy to use.
You just learned how to replace a grill handle step by step.
Gather your tools
Remove the old handle
Install the new one
Test for safety
Tip: Wipe your handle after each use. This keeps it clean and helps it last longer!
FAQ
Can you replace a grill handle without special tools?
You can swap most grill handles with a screwdriver or socket set. If you see rivets, grab a drill.
What if the new handle does not fit my grill?
Check the model number before you buy. If the holes do not line up, you can drill new ones.
How often should you check your grill handle?
You should check the handle before every grilling session. A quick tug keeps your grill safe.
See Also
Essential Tips for Caring for Your Charcoal Grill
Simple Steps to Perfectly Grill Pizza at Home
Transform Your Barbecue Grill into a Pizza Oven
Understanding Inaccurate Gas Grill Temperature Readings and Solutions