How To Fix Hole In Bottom Of Charcoal Grill: 5 Steps Easy Guide

Updated: May 12, 2023


how to fix hole in bottom of charcoal grill

Do you have a hole in the bottom of your charcoal grill? If so, it doesn’t mean you must junk it or buy an entirely new one. With the right tools and know-how, fixing the hole can be surprisingly simple and cost-effective.

The cost-effective and best way to fix the grill is by welding. However, if you don’t have the proper tools for welding or lack the skills for it, you may opt for a patch repair instead.

In this blog post, we will walk you through all of the necessary steps of both methods for how to fix a hole in the bottom of a charcoal grill and help get your charcoal grilling setup back up and running!

How to Fix Hole in Bottom of Charcoal Grill: Step-by-Step Guide (Method 1)

There are many methods to fix the hole in the grill, but the best and most cost-effective way is to weld the hole by using metal sheet.

Here are simple steps for welding the bottom of a grill.

Step 1: Prepare the Grill

Before you begin welding, make sure you properly prepare your grill for the repair job. Clean off any food particles, dirt and debris around and inside the damaged area if possible.

Once clean, use a wire brush, steel wool or sandpaper to remove rust and paint from the area. This will give you an exposed surface for welding.

Once the hole is clear, use a drill bit to make holes around the damaged area. This will help prevent cracking when welding.

Step 2: Gather Supplies

Next, you’ll need to gather the necessary supplies for the job.

Ensure you have welding rods, protective gear (heat resistant gloves, glasses, and a face shield), and an appropriate welding machine.

Step 3: Put on Protective Gear

Now that all your supplies are gathered, it’s time to wear your protective gear. This includes heat resistant gloves, glasses, and a face shield.

Doing this protects you from harm and prevents debris from getting in your eyes and lungs while welding.

Step 4: Begin Welding the Hole

Once your protective gear is on, you’re ready to begin welding the hole in your grill! Start by laying down a bead of weld around the damaged area.

Make sure it’s even and consistent all the way around. This will help ensure a secure bond between the two pieces of sheet metal.

After laying down your bead, use short back-and-forth filler passes to build up the material until you have an even layer that extends slightly beyond the hole area.

This will help create a strong bond and seal up any potential gaps for leaks or debris to get in.

Step 5: Test Out Your Repair Job

Once you’ve finished weld hole repairing process, it’s time to test out your repair job! Start by brushing off any excess weld material and let the area cool. Then, fill your grill with a small amount of charcoal and light it up.

If you don’t smell any smoke coming from the hole or see any leaks, you have successfully fixed the hole in your grill. So, now you may not to worry about how to fix rust holes on a grill.

Can You Fix a Hole in The Bottom of a Grill Without Welding? (Method 2)

Yes, you can fix a hole in the bottom of your grill without welding. If you don’t have the proper tools or skills to weld, then a patch repair is your next best option.

fix hole in bottom of grill without welding

The supplies you will need to patch your grill include some patch material such as:

  • Aluminum Foil or Piece of Sheet Metal
  • Wire Mesh
  • Heavy-Duty Duct Tape
  • High-Temperature Silicone Caulk or Sealant
  • Grinder and Drill with The Proper Bit Size
  • Wire Brush – For cleaning Grill Grates and rust spots

Here are the steps for patching a hole in your grill:

Step 1: Clean the Grill

Remove any loose particles or rust spots from the area around the hole using a wire grill brush and steel wool. Now wipe down the grill surface by using paper towel or soft cloth.

This will provide an even surface for your patch material and ensure it adheres properly to the metal.

Step 2: Cut and Fit Your Patch Material

Cut the patch material to fit the hole snugly. If you are using foil or metal sheeting, it is important to ensure that all corners are tightly secured so that no air can escape.

This will help prevent your charcoal from burning too hot or quickly.

Step 3: Secure With Sealant or silicone caulk

Once you have fitted your patch material, use a high-temperature silicone sealant to secure it.

This will ensure the patch does not come loose and keep your charcoal from burning too hot or quickly.

Step 4: Drill Holes

Using a grinder, drill holes into the patch material. This will ensure the sealant better grip the patch material and stays put.

Step 5: Apply Sealant

Apply the high-temperature silicone sealant around the edges of the patch material and into each hole. Make sure it is spread evenly so that no air can escape.

Step 6: Let the Sealant Set

Let the sealant set for at least 24 hours before using your grill. This will ensure that it is completely sealed and ready to use!

With these simple steps, you can patch a hole in the bottom of your grill without welding.

Other Methods for Fixing Holes in The Grills

Beyond the above two methods, there are more methods about how to fix hole in bottom of charcoal grill are:

  1. Epoxy Glue
  2. Tape
  3. Sealants or High-Temperature Silicone Caulk

Depending on the size of the hole, you can use epoxy glue or tape as a temporary fix until you can weld it shut. For smaller holes, using a sealant is also an option.

What are the Common Causes of Holes and Cracks in The Bottom of Grills

The most common causes of holes and cracks in grills are:


One of the common causes of holes in grill is rust. Rust spots can occur due to long-term exposure to moisture, which can corrode the metal and create holes & cracks.

Accidental Damage:

Another common cause of larger holes in grill is accidental damage, such as dropping the grill or someone stepping on the grill lid.

Wear and tear:

Over time, the metal sheet of your grill can weaken and eventually wear away, leading to holes in the bottom.

Uneven Cooking:

If your charcoal is distributed too evenly or placed too close to the bottom of the grill, it can cause the metal to overheat and cause holes and cracks.

Improper Cleaning:

Using sharp or abrasive material like cleaners on the inside of your grill can lead to holes in the bottom.

Poor Construction:

If the grill is not made with high-quality materials and isn’t properly welded, it can lead to holes in the bottom.

How to Prevent Forming Holes in The Bottom of Your Grill and Maximize The Lifespan Of Your Grill?

Here are some tips for maximizing the life of your grill:

  • Regularly inspect for any holes or damage to the grill surface.
  • Clean and oil the entire grill grates after each use. Grill cleaner is also great option to clean grill grates.
  • Don’t leave your grill exposed to rain or other moisture sources.
  • When not in use, store the grill indoors or with a waterproof cover.
  • Use high-quality materials when building or repairing your grill.
  • Don’t use sharp or abrasive cleaners inside your grill.

Following these easy precautions ensures that your grill lasts as long as possible and remains charcoal grill tip-top shape.

Can I Line The Bottom of My Charcoal Grill With Aluminum Foil?

No, aluminum foil is not recommended for lining the bottom of your grill.

This is because it can reduce the amount of heat circulating in the grill, which could affect how evenly your food cooks.

In addition, the foil can be easily punctured by sharp objects like skewers or spatulas, leading to holes in the bottom of your grill.

It’s best to leave the lining of your grill up to a professional and use only high-quality materials for any repairs.


In the end, I hope you have been able to take something away from this article. With the right tools and know-how, fixing a hole in the bottom of a charcoal grill can be surprisingly simple and cost-effective.

The methods mentioned above are all viable options for patching the hole and getting your charcoal grilling setup back up and running.

It’s also important to take preventive measures when caring for your grills, such as regularly inspecting for any damage or holes.

What can you line the bottom of the grill with?

The best material to line the bottom of your grill is a high-quality metal sheet, such as stainless steel or aluminum.

This will help protect your grill from rust and other types of damage.

Should you keep the lid closed on a charcoal grill?

Yes, it’s important to keep the lid closed on a grill when not in use. This helps to conserve heat and protect the grill from damage.

Should the bottom vent be open on a charcoal grill?

Yes, the bottom vent should be open when using a grill. This allows for proper airflow and helps to ensure that your food cooks evenly.

Can you cook with rust at the bottom of the grill?

No, cooking with rust at the bottom of the grill is not recommended. Rust can be and negatively affect the taste and texture of your food.

It’s best to patch up any holes in the bottom of your grill before using it.



Hello, friends! I'm Kaur, and I welcome all of you. Grilling has been my passion since childhood. After completing my education, I worked as a successful chef for two and half years. However, my dream was to spread the joy of grilling worldwide, and it wasn't possible while working as a chef. So, I decided to run my own grilling shop. Despite this, there were limitations to expanding my grilling experience. Now, I've started my own blog to share my grilling tips globally.

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