When I bought my first house (gosh, maybe seventeen years ago?) one of the first things I wanted was a Kamado. These are ceramic barbeque grills, like the Big Green Egg, that can produce almost magical results grilling, roasting, baking, and smoking. Over the past few years I found myself going to the more convenient gas grill, but after my recent BBQ Fantasy Camp, I wanted to try using the Kamado again.

Unfortunately, my Kamado was pretty run down after so many years outside plus a few moves. The metal hinges and cart were rusty, the firebox was cracked, and the paint very faded. Drawing inspiration from netizens in similar situations, I ordered new replacement parts and spent the weekend rebuilding my Kamado.

Here's my Kamado pre-rebuild. You can see all the rust (and rust stains) on the metal parts. The thing under the grill is the cracked grate (usually inside).

Here's a shot of the cracked firebox inside.

The faded and peeling label.

I took the grill apart and repainted the pieces with black spray paint made for use in high temperature applications. (This is easy to find at hardware stores.) The rectangular hole in the red section below is where I took off the old draft door. The screws holding the draft door assembly on were so rusted I had to cut the heads off with my Dremel; this was probably the most time consuming part of the whole job.

Here's the finished product, with the new hinge band and draft door (at the bottom). I also repainted the wagon and replaced the rusty and bent casters with new ones. Even though I didn't do a great job with the spray paint, I think it looks much better. I ultimately used a little over a can of spray paint for the whole job. I probably should have put a second coat of paint on, but I was too lazy.

This is the interior with a new firebox and grate (the old ring on top of the firebox was still fine, so I'm still using it.) You can also see the nice new lid gasket. I haven't had a gasket on the Kamado for years after the original one burned off. This one is supposed to be a high temperature gasket that won't burn. We'll see.

All told, I probably spent about $300 repairing the grill (replacement cost is about $600) and 4-5 hours. I ran out of time this weekend to cook anything in it, so I'm dying to give a whirl.