Replace Weber Control Knob Without Weber Grill Knobs

by grillrepair on November 16, 2014

Replace Weber control knobs without Weber brand replacement control knobs for the barbecue grill.  We shot these pictures with an old model reminiscent of the original Spirit and Genesis models of 20 years ago and manufactured through 2005.  In 2006 Weber made more changes than any other time — more than all their previous changes combined — and have continued to make changes.  Instead of replacing the barbecue control knob with Weber knobs here we have replaced the knobs with a universal control knob.

Replacement knob attached to Weber control valve looks better and works just like the original knobs

Replacement knob attached to Weber control valve looks better and works just like the original knobs.

This is the universal control knob attached to a Weber barbecue grill.  The knob looks awesome, fits the valve stem perfectly and works exactly the same as the smaller and less attractive original Weber control knobs.

Although the size of the new universal knob is much wider than the original Weber knob the greater diameter does not interfere with the printing on the control panel showing ignition position, high, medium and low settings.  The faux stainless and black grip looks very attractive on the black or the grey Weber control panels.

 

Universal control knob with adjustment inserts for length and stem size

Universal control knob with adjustment inserts for length and stem size on the valve

Weber side burner valve stem matching-up to the knob inserts

Weber side burner valve stem matching-up to the knob inserts

In order to use the universal control knobs we first go through all the white inserts.  Each insert has a different sized “D” shaped opening because there are many different sizes of valve stems to fit into the “D” shaped opening in the bottom of a control knob.  We match the correct insert by trying each on the valve stem exposed once we pull off the original control knob so we have access to the valve stem.  Once we match the correct insert with the proper sized insert we also match the insert that is the correct length.  Some valves have long extensions to reach into the control panel and some valves are already sticking through the control panel so we need the knob to be flush on the bottom, completely flat.

Here we have the insert in the knob and the metal tab lined up with the bolt hole

Here we have the insert in the knob and the metal tab lined up with the bolt hole

Assemble the Control Knob.

To use the universal control knobs we fit the square end of the chosen insert into the square hole in the bottom of the knob.  The knob kit also comes with a small nut and a metal tab.  Slide the metal tab next to the plastic insert so the metal tab is on the side with the threaded hole.  The metal tab has a small lip around the opening that will slide into the threaded hole so the tab is tight and flat inside the square hole in the control knob bottom.  We need a small, long phillips head screwdriver which will thread the bolt into the hole.  The threads in the hole will hold the small bolt and as it is extended into the hole on the inside the bolt presses tightly against the white insert.  In this way the bolt holds the control knob and the insert tightly together so the entire assembly is as tight and secure as though it were a single item.

This allows us to select the length and the sized opening and assemble the knobs to be like one solid product with a variety of different permutations available.

 

With the valve stem available we use the knob inserts to match the "D" size and length

With the valve stem available we use the knob inserts to match the “D” size and length

Although the Weber side burner in the image above has a control valve installed so the valve stem sticks out above the metal control panel the Weber barbecue control panel is mounted above the control valves so the knob has to be able to reach down through the hole in the panel.  For this knob assembly we will need the longer insert, as shown in this image.  Once we have matched the longer valve stem insert that fits the correct sized “D” shape we simply tighten this particular insert into the knob and we have a perfectly designed replacement control knob.

Just like the image at the top of this post, when the control knobs are installed they will be exactly the right size and the functionality of the controls is exactly the same as the original control knobs.  The same is true of the side burner range top.  Even though the side burner has a different type of control valve and a different installation, once we have selected the correct insert for the back of the knob the fit is perfect.

New control knob attached to Weber side burner

New control knob attached to Weber side burner

This control knob is a perfect fit for thousands of brands and models of barbecue grills — including Weber models as seen here — because regardless of which insert we use on a valve stem, the final appearance of the controls is always the same.  There have been plenty of times a client has had an outdoor kitchen with a barbecue grill of one brand and a side burner of a different brand but the models were able to be made to look the same in the custom outdoor kitchen because the knobs are exactly the same.  Even if the design of the appliance it self is different it is the control knobs that most people will notice before the recognize the panels are different or have different logo’s or a different brand of appliance.

We have done this also with brands of BBQ grill whose control valves are no longer available.  When we have to use an after-market valve to replace an original damaged valve we can easily chafe the entire set of control knobs to this universal knob in order to hdd the repaired valve.  Even when the length or the size of the insert os different the knob will always look beautiful and uniform from the outside of the appliance so they will always look the same.

 

Need Help with BBQ Grill Repairs and/or Replacement Parts?

Contact Majestic Grill Parts:

954-2-GRILL-2  which is also 954.247.4552)

Service@Grill-Repair.com

http://www.grill-repair.com

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