Video Assistance for Replacement Control Valve Gasket Installation To Repair BBQ Grill Gas Leaks.

Although there are several different methods for a barbecue grill control valve to be installed into a gas barbeque grill, the connection we are concerned with today is the very common clamp-on connection.  Inside the control panel of a gas BBQ is the gas manifold pipe connected to your fuel and each control valve clamps on to this manifold pipe to pull fuel from the manifold pipe into the grill burner.    The manifold pipe has a small opening for the valve to slide into and a round o – ring gasket seals this opening so no fuel leaks from the control valve connection.

Control valve gasket seals gas flow from manifold into valve

Control valves that clamp onto manifold gas pipe have o-ring gasket to seal gas pressure.

Shown here, the gasket is red and is installed just inside the rounded top section of the clamped section of this grey aluminum control valve.    All lamp on valves have this same gasket; they are not usually red.    As we can see in this image the manifold pipe installed across the barbecue grill control panel has a lot of discoloration which is almost always the case in every outdoor appliance.   Over time the manifold will become dirty, rusty, corrosive even though it is not in the cooking area of the fire box.   This can cause problems with the tight seal of the gasket or even when installing the valve as shown here.   Make sure the manifold is clean because a single drop of grease or a bubble of rust-spotting can interrupt the gas seal.



rounded edge of gasket matches manifold pipe

Install valve gasket so gasket curve matches rounded manifold pipe.

The most common reason we will have to examine inside the control panel for fuel leaks at the control valve and valve gasket is heat from our BBQ.   When a barbecue is cooking with the lid down heat is usually being vented at the back of the closed lid so there is a limit to how much heat can build up and stabilize at any time.

Often when the back of the barbecue faces the ocean or any area that allows wind to blow at this back hood ventilation, the hottest part of convectional heat is unable to be pushed out of the grill.    Heat will leak forward into the control panel where it is well known to damage ignition wiring, valve lubrication and these sealed gaskets.

Remove and clean inside the valve for ne gasket installation.

Remove and clean inside the valve for new gasket installation.

Depending on how much heat has been pushed into the control panel area, a control valve stem, which connects to the knob, will eventually become sticky and “freeze” because of damage to the internal lubrication.   The gasket allowing a very minute fuel leak is typically a more immediate problem.

If the gasket is permitting fuel to leak. this can cause a typical LP tank’s safety features to become activated so the propane does not flow properly to the manifold but the bigger problem is if the fuel does flow and leaks inside the control panel while also feeding fuel through the manifold pipe, control valves, and into the barbecue grill burners.    Obviously this is highly dangerous because we will ignite the BBQ and witness the burners as if all is functioning properly without seeing there is fuel flowing inside the control panel which will eventually ignite.

Remove the gasket that has been damaged so the inside of the control valve clamp is clean and reinstall the new gasket so the curve of the gasket mirrors the curvature of the manifold valve.

Always tighten Very Well and Always check for leaks!

Need any assistance or have any questions, Contact Majestic Grill Parts.



Video installation instructions for Turbo barbecue repair control valve installation in models like the BBQ Galore Turbo Challenger, STS, Elite and other grill models.

This Turbo control valve has been discontinued and the last of the replacement valves have been installed so the replacements are extinct.  Because we still have a lot of clients contact us for this replacement control valve necessary for BBQ Galore BBQ grill repairs, wee have worked with a handful of other replacement valves until we discovered a valve we could use to repair these Challenger, STS, Classic, Turbo Elite and other barbeque models.

Fortunately, the replacement control valve Also fits the original control knobs and the original LP and NG orifices!

Original Turbo STS and Challenger barbecue grill control valve.

Original Turbo STS and Challenger barbecue grill control valve.

In this image we can see the original control valve attached to the manifold pipe.   This image is from the original Turbo STS model by BBQ Galore.  Over several years there have been several different versions of STS models sold by BBQ Galore.   This is the first version of the Turbo STS which has a separate ignitor assembly so the control valve has nothing to do with the parts that cause ignition in the BBQ grill.    Later Turbo STS models has Two different control valve designs but both of the later Turbo STS control valves have an integrated igniter built into the design of the control valve.  Only the first Turbo STS model has these control valves that do not trigger the sparking that will ignite the gas burners.

Clamp on installation valves tested to replace Turbo control valves

Clamp on installation valves tested to replace Turbo control valves for Challenger and STS models.

These models are very old and the one shown here is a barbecue a local customer asked us to dispose of for them.  Instead of a dump-site we brought the barbecue back to our warehouses to repair and clean and eventually give away looking brand new with all new parts.  For now we removed the seriously damaged manifold pipe and coated it with a heavy viscous paint to protect the badly corroded manifold pipe.

Once the gas manifold was clearly going to be able to be used again we started testing control valves.  Several valves seemed capable of working but as shown in the image here, using any of these other control valve replacements would necessitate also replacing the gas orifices and the knobs with every valve which would increase the repair costs considerably.  We could Make these control valves function in these barbecues but the replacement would be more expensive and complicated than necessary.

So we kept trying…

The control valves we Did finally install has the Same valve stem to fit the original control knob (if desired) and the same threading for the gas orifice which determines if the valve will control propane or natural gas.  As we show in the installation video above we can re-use the original gas orifices and the original control knobs.

replacement gas control valve with ignition momentary integrated to valve stem

replacement gas control valve with ignition momentary integrated to valve stem

More importantly we can identify these pieces so the controls Are Able to be replaced just as we can Very Easily Replace the orifices if we need to convert the type of fuel the barbecue grill is using.    Other valve options has other benefits but this is the valve that will function most like the original.

Need a control valve to repair a Turbo barbecue grill model of STS or a Challenger, Elite, Classic or some other replacement?  The URL above will easily transport Your Browser to a page of our site where these control valves are available along with other versions of the Turbo models and other parts for ignition, burners, briquette trays and supports and anything you could need to repair any Turbo barbeque model and get back to cooking!

From this page we can also transport to a page of replacement BBQ grill burners and to a page of briquettes and supports cooking grates and contact experts for any assistance necessary.



Rotisserie Thermocouple Valve Keeps Turning Off Burner – Explanation Repair and Use.

Often customers contact us for assistance because a infrared rotisserie burner will turn on but then turns itself off when the control knob is released.   Rotisserie infrared back burners should keep burning until we turn them off!     Usually when a client contacts us with this complaint the assumption is that the thermocouple is not functioning or the burner is damaged but about ninety nine percent of the time neither of these are problematic.    The safety feature of the control has a spring loaded solenoid which can be easily damaged, even inside the body of the valve.

What we are trying to demonstrate here is what and where and how this works but also how to “cheat” past this safety mechanism — but do not do this at home.   This is more like a thought experiment or something a highly experienced, licensed (and insured) gas technician may consider but what we show here is meant as a thought experiment showing functionality and processes, not instructions to follow.

The hood of a gas grill is designed so the hottest part of  convectional heat takes the widest diameter circulation and flows out the back of the gap behind the grill hood.    When wind is blowing off the ocean or across a lake or simply blowing in this direction it can easily hinder the ability for this hottest air circulation to escape.    Over time our control valves will get sticky and will eventually “freeze”, or stop turning because over time the lubrication has been slowly damaged by this heat.

The rotisserie valve solenoid is a lot more fragile.   While the control valve sin this environment could take 7-10 years to “freeze” the rotisserie solenoid has a thin plastic housing around the copper coil and iron core and this is very easily warped by heat.

Although not easy to see without un-assembling the rotisserie control valve, this solenoid is often exactly the reason the rotisserie turns the burner off when ever we remove our hand from holding down the control knob as shown in the repair video above.

Need Help?

Replacement Parts?

Contact Majestic Grill Parts







The gas barbecue grill Elite models by OCI were truly exceptional gas grills with tremendous longevity and legendary design features.     Unfortunately the stability of the company did not last and these awesome grills did not remain in fabrication for even a decade.     The video instructions below demonstrate how to remove the control panel from an Outdoor Concepts, Inc.  gas barbecue grill.

OCI gas grill parts are shown described sold and shipped from:

oci gas bbq grill repair parts

The OCI gas barbecue grill Elite models include the E36 and the E48 which both integrate a pressurized infrared burner at the far right side of the grilling surface.      Infrared gas burners will typically heat above One Thousand Degrees inside Two Minutes!    Grilling at searing temperatures is what these are made to do.   The U burners in an OCI gas bbq grill are also able to be very hot and these U shaped burners have heavy stainless steel rod trays installed above the burners so the convectional heat coupled with the conductive heat radiating off these all stainless rod trays in enormous has the ability to grill above restaurant-quality searing temperatures even without the infrared burner.

However, the OCI Elite models also have a smoker and a rotisserie with their own dedicated burners and cooking system accessories.    These OCI gas barbecue grill models were made to be fully capable of every and any kind of cooking style and at any type of temperature type and temperature level.    Of course the goal of this particular post is not to be a cheerleader for OCI grills but showing the information in the video tutorial above.

OCI control panel bbq grill repair parts

OCI Control Panel Design Does Not Seem To Have Any Hardware Holding The Control Panel In Place.

The OCI Elite models control panel always had a nice clean appearance without bolts or screws at the four corners.  There are no visible means of production across the control panel.     Only when we need to repair something or access the control area for some reason do we realize we need to understand how the control panel is removed — and removed properly.

Inside the OCI control panel.

Inside The OCI Control Panel We Can See The Rotisserie Controls, Burner Valves, Ignition Assembly, Gas Manifold, and Access Anything Necessary To Repair The Grill Or Adjust Performance.

As we will have seen in the instructional video shown above, the lower drip tray slides completely out so we are able to look up inside the control panel and realize each far side of the control panel has 3 bolts holding each side in place — this is a Lot when compared to other gas grills and is really a bit much when the overall design makes to seem as though there is no hardware at all!

Six Bolts holding the control panel in place!

Fortunately, as shown in our tutorial video above, we really only have to actually extract the very lowest left and the lowest right side bolts.

Once the lowest left and right side bolt is removed from under and behind the control panel — easier typed than accomplished but not too bad I promise — the rotisserie button and the rotisserie bezel Must Be Removed with the control knobs.

Now suitably naked, the control panel will shift about a half-inch up and slide out of the front of the gas grill. Try to keep the left and right side even so the cut-out “L” shaped slot does not get caught with tension from one side getting too far ahead.     It is possible to keep the control anel perfectly straight and level by sliding up and then sliding out the lower bolt before the higher bolt which is how we pull the control panel out in the video.

Once the control panel is free the only resistance will be determined by the length of the momentary switch button wires which simply pull free.

Need Any Help or Have any Questions?

Contact Majestic Grill Parts  —

OCI gas grill parts are shown described sold and shipped from:

oci gas bbq grill repair parts



Repair OCI Elite E36 and E48 barbecue grill models with brand new U burner installation.

Video Instructions Shown Below.

In the images below we repair a barbeque grill by Outdoor Concepts, Inc by installing a new U burner which comes with a back mounting bracket and elongated orifice to provide additional support.

New U burner installed in e36 and e48 OCI barbecue grill models.

New U burner installed in e36 and e48 OCI barbecue grill models.

Although the u burner can be installed without the new orifice and back mounting bracket we install the burner with these items because this makes the installed burner tightly mounted and unable to be moved in any direction once installed.

The orifice is exactly the same as the size and threading that comes already installed in the OCI barbecues but is about twice as long as a normal orifice so the burner has extra support.

Behind the burner we use a u-clamp “L” bracket that will sit directly on top of the existing burner support ledge.  Although it is work to place holes into the back wall of a grill that has such high-quality and thick stainless steel, with the correct tools this is not very difficult.    As shown in this instructional video, we score the wall location with a marker and then use a steel hole drill-bit which is designed to make large and larger holes even though we only need a hole about 3/16″.    We use the pyramid-like hole drill-bit because the tip cuts through the 304 type 18 gauge stainless steel without spending a lot of time doing so.    When I first did this with self-tapping screws as we easily use through galvanized steel, I lost a Lot of time and Still dip not have the hole I wanted.


OCI control valve to orifice into U burner with new orifice on valve

OCI control valve to orifice into U burner with new orifice on valve

Although the burner installed in the OCI Elite gas bbq grill models is a great fit, the support clips are not the same so  we use the back support bracket for additional stability on the back wall whereas the front support is the longer orifice added to the tip of the control valve as shown in the video directions.     What we do not generally see inside a gas grill control panel is the control valves attached to the gas manifold pipe and the orifice attached to the valve where the burner air shutter slides over the orifice.

When we remove and install the orifice, we do not need to expose all these inner workings of the inside of the control panel because we can simply reach through the inner firewall to unscrew the orifice and thread on a new orifice.    The new, longer gas orifice will be about twice as long as the original and slides into the air shutter of the new U burner as shown in the video installation instructions and the image shown here.

New OCI grill burner installed in bbq

New OCI grill burner installed in bbq.

Once the new U burner is installed the setting is simple and fits inside the space created by the ignition cross-over tube brackets.  If you have an OCI barbeque grill model you already know these crossover electrodes do not always ignite quickly because fuel has to flow into the crossover tube to reach the electronic sparking electrode.

oci burner installation and igniter electrode

New U burners fit without changing or adjusting width of ignitor electrode cross over bracket.

In this image of the infrared burners glowing you can also see we have replaced the OCI smoker pipe burner.  We replaced the ignition electrode so the smoker burner ignites quickly and easily when we installed the smoker burner.

These OCI U burners are simple to install safely and Outdoor Concepts, Inc made some of the best grills of their time so these are absolutely definitely barbecue grills are worth repairing and continuing to use.

OCI gas grill replacement parts can be found on our site at the following URL address:

If you have any questions or need any assistance or anything at all — bbq grill related! — please contact us with:



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