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Grill Keeps Rusting? A Good Cover Is the Cheapest Defense

Moisture, wet ash and grease eat a grill inside and out. Keep it dry and oiled, then a fitted, vented cover guards it between cooks.

By Jamilur Rahman Updated November 5, 2026 · 6 min read

Time
30 min
Cost
$20-$50
Difficulty
Easy
A backyard grill with orange rust spots on the lid and legs, and a folded cover on a table nearby
In this guide
  1. Quick answer
  2. Free vs. permanent fix
  3. What you'll need
  4. Why it happens
  5. Try this first (free)
  6. When free fixes aren't enough
  7. Buy the fix
  8. How to measure for a grill cover
  9. What to skip
  10. FAQ
  11. Related problems

Quick answer

Why does my grill keep rusting? Moisture sits on bare metal, and wet ash, grease and rain make it worse. Burn off and brush the grates after cooking, empty the cooled ash, dry the grill and wipe on a thin coat of oil. A heavy-duty, vented cover keeps rain and dew off between cooks, which is the cheapest way to stop rust from coming back.

Free fix vs. permanent fix

Free fix · 10 minutes after each cook

Burn off, brush, oil and dry

  • Burn off the grates and brush them after cooking
  • Empty cooled ash and grease
  • Wipe a thin coat of oil on bare cast iron or steel grates
  • Dry the grill before you put it away

How long it lasts: As long as you do it and the grill stays dry. A grill left uncovered in rain still rusts.

Most readers choose Permanent fix
Heavy-duty vented grill cover (illustration)
Illustration

A heavy-duty, vented grill cover

Most grill rust comes from rain, dew and humidity sitting on bare metal. A fitted cover keeps the water off, and vents let trapped moisture escape so the cover does not cause the mold it is meant to prevent.

What to get: Heavy-duty vented grill cover

How long it lasts: A few seasons per cover. Replace it when the fabric cracks or tears.

Check price on Amazon

As an Amazon Associate I earn from qualifying purchases.

What you'll need

  • Nylon-bristle grill brush or scraper

    Avoid worn wire brushes that shed bristles

    You have it

  • Cooking oil

    Any high smoke-point oil works

    You have it

  • Steel wool for exterior rust spots

    Outside surfaces only, never the cooking grates

    You have it
  • Our pick
    Heavy-duty vented grill cover (illustration)
    Illustration

    Heavy-duty vented grill cover

    Size it to your grill

    Check price
  • High-heat rust-resistant spray paint (illustration)
    Illustration

    High-heat rust-resistant spray paint

    For bare spots on the outside of the grill

    Check price

Why it happens

1

Rain and dew on bare metal

A grill left outside gets wet over and over. Any chip in the paint or enamel gives moisture a place to start rust.

2

Wet ash and grease

Ash holds moisture against the bottom of the grill and grease holds dirt, so rust starts in the firebox and the grates.

3

Cooking surfaces left dirty or wet

Food residue holds water. Rinsing a grill and putting it away wet leaves moisture in the grates.

4

Humid air, sprinklers or salt

Coastal air, wet climates and a spot in range of a sprinkler speed up rust.

5

A cover that traps moisture

A thin, unvented cover put on a damp grill holds condensation against the metal.

Try this first (free)

Do these in order, starting with the simplest.

  1. Burn off and brush the grates

    Tool used: Nylon-bristle grill brush or scraper

    After cooking, run a gas grill on high for 10 to 15 minutes with the lid down. Let it cool a little, then brush the grates. Check the grates for loose bristles before the next cook.

  2. Empty the ash and grease

    Once the grill is fully cool, empty the ash into a metal container and clean the grease tray. Do not leave ash sitting in the bottom, since it holds moisture.

  3. Oil the grates lightly

    Tool used: Cooking oil

    Wipe a thin coat of high smoke-point oil on cool, clean cast iron or steel grates. Porcelain-coated grates need less oil.

  4. Scrub exterior rust and touch up

    Tool used: Steel wool for exterior rust spots

    Rub small rust spots on the lid, firebox or legs with steel wool, wipe clean and touch up with high-heat paint. Do not paint the cooking grates.

  5. Cool, dry and then cover

    Tool used: Heavy-duty vented grill cover

    Let the grill cool fully and make sure it is dry, then fit the cover. Put the grill where sprinklers and roof runoff do not reach it.

    Heavy-duty vented grill cover (illustration)
    Illustration

    Tool for this step

    Heavy-duty vented grill cover · Size it to your grill

    Check price on Amazon

When free fixes aren't enough

Cleaning and oiling slow rust, but they cannot keep rain off. If the grill lives outside, rust returns after each wet week however well you scrub it. Cheap, thin covers can trap condensation. Look for heavy-duty fabric with vents and straps that hold in wind. Rust that has eaten through the firebox, burner tubes or legs, or flakes that fall onto the cooking surface, is a reason to replace parts or the grill. On a gas grill, check hoses and connections by brushing on soapy water. Bubbles mean a leak. If you smell gas, shut off the tank and call the gas supplier or the fire department.

Buy the fix

Still stuck after the free fixes? These are the products we would look at.

Our picks compared
PickProductFixesWho it's forBuy
Best pick
Heavy-duty vented grill cover (illustration)
Illustration
Heavy-duty vented grill cover
rain, dew and sprinkler water sitting on bare metal Anyone who leaves the grill outdoors. Check price
Budget pick
High-heat rust-resistant spray paint (illustration)
Illustration
High-heat rust-resistant spray paint
bare patches on the outside of the lid, firebox and legs Owners with small rust spots on the outside that they have already scrubbed. Check price
Best pick
Heavy-duty vented grill cover (illustration)
Illustration

Heavy-duty vented grill cover

Fixes: rain, dew and sprinkler water sitting on bare metal

Look for: Sized to your grill, so measure width, depth and height; Water-resistant, UV-resistant fabric with a soft lining; Vents to let moisture escape; Straps or a drawstring to hold it in wind.

Who it's for
Anyone who leaves the grill outdoors.
Honest downside
The grill is still warm, since the cover must go on only when it is fully cool. If the grill lives in a dry garage, wiping it dry may be enough.
Check price on Amazon
Budget pick
High-heat rust-resistant spray paint (illustration)
Illustration

High-heat rust-resistant spray paint

Fixes: bare patches on the outside of the lid, firebox and legs

Look for: Rated for grill temperatures on the label; A rust-inhibiting formula for metal; Labeled for outside surfaces, not cooking grates.

Who it's for
Owners with small rust spots on the outside that they have already scrubbed.
Honest downside
Rust is on the grates or inside where food touches, or it has eaten through the metal. Replace those parts.
Check price on Amazon

As an Amazon Associate I earn from qualifying purchases. We don't show prices because they change, so use the button to see today's price.

How we picked: How we picked: this page is based on grill maker care guides, cover and paint spec sheets, and the problems and fixes people report in reviews. We do not test products by hand.

How to measure for a grill cover

  1. Width: side to side, including side shelves.
  2. Depth: front to back with the lid closed, including the handle.
  3. Height: from the ground to the top of the lid.
  4. Compare to the listing, or match your grill's model name. A cover that is a little roomy is better than one that strains.

What to skip

Hosing a hot grill and using an unvented tarp

Cold water on hot metal can warp it, and a tight tarp traps condensation against the grill, which sets rust and mold up. Let it cool, dry it and use a vented cover.

Frequently asked questions

How to stop a grill from rusting?
Keep it dry. Brush and oil the grates after cooking, empty cooled ash, touch up chipped paint and use a fitted, vented cover. A spot out of the rain helps too.
Why does my grill get moldy?
Mold needs moisture, food residue and little airflow. Leftover grease and a closed lid in humid weather are the usual mix. Scrub with warm soapy water, rinse, dry it, then burn off on high for 15 minutes.
Is it safe to use a grill with surface rust?
Light rust on the outside is a cosmetic problem. On grates, scrub off flakes, burn off and oil them. If the grates keep flaking or the firebox has rusted through, replace the part.
Is a grill cover worth it?
Yes, if the grill lives outside. A fitted cover keeps most rain and dew off, which is where rust starts. Choose a vented one so moisture can escape.

As an Amazon Associate I earn from qualifying purchases. Affiliate disclosure

Heavy-duty vented grill cover (illustration)
Illustration

Our pick: Heavy-duty vented grill cover

Check price