Grill Repair: Convert to Natural Gas

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Converting your BBQ Grill from Propane to Natural Gas

You’ve got yourself a propane grill, but you’re eyeing the natural gas hookup. First off, kudos for thinking ahead! Converting is like leveling up your grilling game.

 

Interchangeable gas valve orifices on bbq gas grill manifold

The Meat of it All

If you are interested in converting your grill, you'll need a conversion kit. The best place to start is to contact your manufacturer or the dealer where you purchased your grill to assure compatibility. Kits usually include a new regulator, hose, and natural gas orifices for your burners. Your grill manufacturer might sell these, or you can find third-party kits.

Fundamentals

There is no single and easy way to safely or properly convert your grill by simply drilling the orifice or changing the supply line. All components have to be considered to maintain the integrity and safety of the system. Gas grills, like any other appliance, are designed and engineered to definite specifications with specific components. Scroll down for more information about orifice sizes and flow characteristics.

Get to know your Nameplate

typical bbq gas grill nameplate

Nameplate Data: You’ll need this vital information for the conversion kit you’ll be tracking down.
BTU Ratings: Grill models are individually designed to operate at specific BTU ratings. The BTU rating is a measurement of how much heat your grill will generate and this rating can be found on the nameplate data on your grill. The nameplate data may state the BTU rating in two different ways - as per burner or as a total rating for the grill. As an example the rating may be 40,000 BTUs total or 20,000 BTU’s per burner. (This becomes particularly confusing when you model incorporates a "dual" burner which is manufactured as a single unit with each side individually controlled by it’s own control knob. In this case each side would have a 20,000 BTU rating for a total of 40,000 BTUs.) Typical grills don’t exceed 40,000 BTUs, but there are many high-heat exceptions.
Your Grills Warranty, Certification and Design: In the majority of cases if you change the supply type or convert your grill from one type to another you will void all warranties and certifications. Gas Grills are designed and certified to operate on a single type of gas supply. The type of gas will be shown on the nameplate data. Some premium brand manufacturers offer conversion kits and will not eliminate your warranty. Check with your local dealer or the manufacturer.

Scroll down for more information of Gas Conversion

Converting the gas supply to your BBQ grill

Why Go Natural?

Natural gas is a constant buddy. No more running out of propane in the middle of your epic BBQ. It’s like having an unlimited supply of grilling power.

The How-To Overview

Now, this isn’t a task for the faint of heart. Converting takes some handy skills and a pinch of patience. Here’s the roadmap:
  • Safety First: Always, always, always prioritize safety. Turn off the gas supply and disconnect the propane tank from your grill.
  • Check Compatibility: Make sure your grill is compatible with natural gas conversion. Not all grills can make the switch.
  • Get the Kit: You’ll need a conversion kit. It usually includes a new regulator, hose, and natural gas orifices for your burners. Your grill manufacturer might sell these, or you can find third-party kits.
  • The Swap: Now comes the fun part – swapping out the parts. Replace the propane regulator with the natural gas regulator and hose. Install those natural gas orifices into your control valves. It’s like giving your grill a new set of lungs.
  • Test the Waters: Once you’re all set, do a gas leak test. Mix some soapy water, apply it to the connections, and turn on the gas. If you see bubbles, you’ve got a leak – tighten things up.
  • Call in the Pros: If you’re not 100% confident, it’s okay to call in a professional. They’ll make sure everything’s shipshape.
Enjoy The Perks: Enjoy the blaze of glory! Natural gas grilling means no more propane tank swaps, and you’re doing your bit for the environment – it’s a win-win!

Tech Notes: BTU and Oriface Size Guide for BBQ Grill Gas Conversion

gas grill oriface size stamp

Orifice Size and Stamp

The valve orifice fitting is the fitting at the end of the valve which has a small hole drilled into it’s center. The orifice size is the actual hole diameter in the orifice fitting. Most orifice fittings will have their size stamped either on the top or side of the fitting.

Calculated BTU Output

The actual BTU output is determined by the pressure of the gas supplied, volume of gas which is regulated by the valve and by the orifice fitting orifice hole size. As an example, assuming a fixed natural gas pressure of 3.5 inches of water column a #48 orifice will give a different BTU output than a #46. (Altitude also affects the BTU rating.)

Oriface Sizes and Modification

Drill bits are available by size number, and their sizes have an inverse relationship. The larger the number, the smaller the drill bit. (Orifice hole size will be larger for natural gas supply models than propane because of the lower natural gas operating pressure). Thus a #56 size orifice is an orifice fitting that has been drilled with a #56 drill bit.

BTU and Orifice Size Guide

btu and oriface sizing guide