Grilling season is here again! It’s time to enjoy tasty food, warm weather, and fun with family and friends. But before you get too excited about cooking outside, don’t forget about something important: your grill cover. A quality grill cover is your first line of defense against the elements, dirt, critters, and rust. Yet, many grill owners unwittingly commit blunders that shorten the lifespan of both their grill and the cover meant to protect it.
Knowing how to protect your grill with a cover the right way can save you from costly repairs and keep your BBQ gear in top shape. In this blog, we’ll explore five common mistakes you might be making with your grill cover and more importantly, how to fix them.
- Using the Wrong Size Cover
It might seem like a cover is a cover, right? Wrong. Using an ill-fitting cover is one of the most common mistakes when using grill covers. A cover that’s too tight can tear or put stress on seams. A loose cover, on the other hand, invites wind, moisture, and critters to slip in underneath.
Always opt for custom grill covers that are measured precisely to your unit’s dimensions. Customization ensures that every inch of your grill from side burners to warming racks is adequately protected. While you’re at it, consider coordinating outdoor kitchen covers if your barbecue is part of a larger setup. Investing in custom-fit protection pays off in extended lifespan and better resistance against outdoor exposure.
2. Neglecting Ventilation Needs
Most people don’t realize that a grill cover needs to breathe. Without proper airflow, condensation forms beneath the cover, creating a humid environment that encourages rust, mildew, and corrosion. This issue is a top reason why your grill cover isn’t working the way it should.
Good grill covers come with built-in vents or mesh panels to allow air circulation while still keeping rain and debris out. Additionally, you can also pair your grill cover with ventilated options like fire bowl covers which are also prone to moisture buildup and can inspire a consistent approach to outdoor gear protection.
3. Covering a Wet Grill
Ever come back from a cookout and immediately toss the cover back on your grill without letting it cool and dry? Storing a grill while it’s wet is a fast track to rust, even under a cover. It creates the perfect environment for corrosion, especially if your cover doesn’t ventilate well.

This mistake highlights how to avoid grill rust with proper covering. Always wait for your grill to cool completely and make sure all surfaces are dry before covering it. This rule applies to your other outdoor gear too. For example, let outdoor cushion covers dry fully after a rain before putting them back on.
4. Dragging the Cover Across Rough Surfaces
If you remove your grill cover and let it drag across concrete or stone, you’re inviting unnecessary damage. This wears down the material, causes rips, and can damage protective coatings. Over time, your once-durable cover becomes a flimsy sheet.
To maintain its integrity, always lift the cover off carefully.
Pro Tip: This rule applies not just to grill covers but also to firewood covers and equipment Covers that often get tossed aside during busy yard work.
5. Ignoring Cleaning and Maintenance
A custom fit cover is your grill’s best friend as it shields your grill from dirt, bird droppings, pollen, and weather elements. But if you never clean it, all that grime builds up and starts breaking down the material. Eventually, mold and mildew set in, compromising its functionality and aesthetics.
Regular maintenance is part of grill cover care and cleaning tips that every grill owner should follow. Clean the cover with mild soap and water every few weeks, especially during peak usage months. Always allow it to dry thoroughly before placing it back on your grill.
You can apply the same diligence to other outdoor essentials. For instance, patio furniture covers and outdoor sofa covers benefit from the same cleaning regimen, especially when left exposed for long durations.
6. Picking the Wrong Material
While price is always a factor, opting for a cheap, thin grill cover is often a false economy. Low-grade materials can’t withstand UV exposure, wind, or heavy rain. They crack, tear, and fade quickly leaving your grill vulnerable.
This points to the importance of selecting the best material for grill covers. Look for UV-resistant fabrics, reinforced seams, and waterproof coatings. Materials like PVC-coated polyester or solution-dyed acrylics are great choices that balance durability with breathability.
Tips for Protecting Your Investment
Now that you know what not to do with your grill cover, here are a few proactive tips to ensure your setup remains in top condition:
- Anchor your grill cover properly with straps or drawcords to prevent it from flying off in windy weather.
- Store the cover indoors during prolonged periods of non-use, like winter months or extended vacations.
- Conduct seasonal inspections to check for cracks, seam separations, or fading.
Conclusion
From choosing the wrong size to skipping basic maintenance, these mistakes might seem minor but can lead to costly damage over time. Being proactive with your grill cover practices ensures your beloved barbecue station is always ready to sear up a storm without succumbing to rust, wear, or decay. With the right materials, regular care, and mindful use, your grill cover will serve you well through many summers to come.
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