How to Assemble a Propane BBQ

How to Assemble a Propane BBQ. While the secret to assembling most propane BBQ grills involves reading the owner's manual carefully, a majority of propane grills share a similar design and can be constructed the same way.

You should be able to assemble a new propane grill in an hour or two, and be cooking like a true grill master shortly afterward.

  1. Assemble your new propane BBQ grill in the same area in which you will use it. Choose an outdoor area that is away from buildings, trees, bushes, power and phone lines. The ground should also be level and free from grass or other flammable materials.

  2. Lay out all of the parts of your new propane grill, and conduct an inventory against the parts list in the owner's manual to ensure that nothing is missing. Avoid throwing away any packing materials or the carton until you have assembled the grill and seen that it is working to your satisfaction.

  3. Gather the tools you will need to assemble the propane BBQ grill. In most cases, this will just be a screwdriver and a small adjustable wrench.

  4. Follow the instructions in the owner's manual to assemble the grill. With many models of propane BBQ grills, you will start by attaching the main housing to the base or rolling stand. You may want to ask someone for help to steady these large pieces while you tighten the hardware.

  5. Install the burners into the main control panel, taking care to inspect the burners for cracks, corrosion or enlarged holes. The burners will usually snap into the control valves quite easily, with the built-in igniter unit eventually added to this assembly.

  6. Attach the side tables and lid during the later steps of assembly of your new propane grill. You will also add any decorative items and accessories at this point, including handles, accessory compartments and hooks.

  7. Install the cooking grates and the propane tank as the final steps when you assemble your new propane BBQ grill. Ensure that the propane tank is secure underneath the grill, and that the attached gas line and valve work properly. All seals and connectors should tighten satisfactorily as well.


Most new propane grills come with empty propane tanks for safety reasons. Plan on having your new tank filled from the store where you bought it, or have it exchanged for a full tank at any propane retailer.