Rust forming inside cook chamber, on grates, or on heat baffle.

Safety first: Work on a cool grill and wear gloves when handling rusty metal.

• Step 1 – Remove loose rust: Use a wire brush or abrasive pad to remove surface rust from grates and internal parts.
• Step 2 – Re-season grates: Coat cast-iron or steel grates with high-smoke-point cooking oil and run the grill at 350–400°F for 30–60 minutes.
• Step 3 – Protect surfaces: After each cook, lightly oil grates and store the grill under a Pit Boss cover.
• Step 4 – Replace severely corroded parts: If rust has compromised structural integrity, replace affected parts such as cooking grates or heat baffle.