How to Convert a Gas Grill to Infrared

Transforming a conventional gas grill into an infrared powerhouse unlocks unprecedented searing power, even heat distribution, and juicier results. Infrared burners emit radiant heat directly to food, bypassing air heating for faster cooking and retained moisture. This guide explores the process comprehensively, from understanding the technology to executing the upgrade safely at home.

Understanding Infrared Grilling Technology

Infrared grilling uses ceramic or metal emitters that glow red-hot, producing intense radiant energy around 1,5006F. Unlike traditional burners that heat air, infrared penetrates food surfaces instantly, locking in flavors while cooking interiors gently. This method excels for steaks, burgers, and veggies, reducing cooking time by up to 50%.

Key advantages include precise temperature control, minimal flare-ups, and fuel efficiency. Home cooks appreciate the restaurant-quality sear without a commercial setup. However, retrofitting requires matching components to your grill model for safety and performance.

• Radiant Heat Efficiency: Direct energy transfer minimizes heat loss.
• Versatility: Ideal for high-heat searing or low-and-slow roasting.
• Durability: Ceramic plates resist corrosion better than standard cast iron.

Assessing Your Grill for Conversion

Before starting, evaluate your grill’s compatibility. Most propane (LP) or natural gas (NG) models from brands like Sunstone or Fire Magic support infrared kits. Check the manual for convertible valves and burner spacing. Measure burner tubes and orifice sizes1typically #50 for infrared.

Inspect for wear: Rusty valves or warped frames signal a full replacement over conversion. Gather tools like 6mm/7mm wrenches, pipe compound, screwdrivers, and a conversion kit specific to your grill size (e.g., 34-inch 4-burner).

Essential Tools and Materials Checklist

Proper preparation prevents mishaps. Stock these items:

• Conversion kit (orifices for main, rear infrared, side burners)
• Adjustable wrench set (6mm, 7mm nut drivers)
• Pipe thread sealant (natural gas approved)
• Screwdrivers (Phillips/flathead)
• Cotter pins, electrodes if needed
• Indelible marker for rating plate
• Safety gear: Gloves, goggles

Avoid generic kits; opt for manufacturer-approved ones to ensure pressure ratings match (LP: 11″ water column, NG: 7″).

Step-by-Step Infrared Burner Installation

Work in a well-ventilated area with the grill cold and gas disconnected. Follow these phases meticulously.

Phase 1: Prep and Access Burners

1. Disconnect gas source completely.
2. Remove grates, flame tamers, and drip tray for full access.
3. Slide out main burners by releasing cotter pins—expose brass orifices at valve ends.

Phase 2: Orifice Replacement

Orifices control gas flow; infrared demands smaller holes for higher velocity.

1. Unthread old orifice with 6mm socket (main burners).
2. Apply pipe compound to new infrared orifice threads.
3. Hand-tighten, then wrench snugly—do not overtighten to avoid stripping.
4. Repeat for rear rotisserie burner: Access via back panel screws.

For dual infrared setups, change both #52 orifices similarly.

Phase 3: Regulator and Valve Adjustments

Flip the regulator plunger: Remove cap, reverse for NG/LP orientation, and reseat firmly.

1. Tilt grill forward to access rear regulator.
2. Swap LP line if crossing fuels.
3. Reinstall with secure fittings.

Phase 4: Electrode and Wiring for Ignition

Infrared burners need hot-surface ignition.

1. Remove old electrode from control panel.
2. Mount new assembly to burner tabs with bolts/nuts.
3. Route wires to igniter module, connecting bare ends securely.
4. Test continuity before closing up.

Note: Discard flavor grids over infrared—they block radiant heat.

Phase 5: Reassembly and Labeling

1. Reposition burners, aligning slots.
2. Replace grates, trays, and panels.
3. Mark rating plate as “Infrared Converted” or “NG/LP”.
4. Apply conversion label inside fire wall.

Safety Protocols During Conversion

Gas handling demands caution to prevent leaks or fires.

• Leak Test: Mix soapy water, brush connections, and check for bubbles post-assembly.
• No Open Flames: Perform all work unplugged and outdoors.
• Pressure Check: Verify with manometer—NG 5-10″, LP 10-12″.
• Professional Help: If unsure, consult certified technician.

Common pitfalls: Cross-threading orifices or mismatched kits cause uneven flames or blowouts.

Troubleshooting Common Conversion Issues

Run a 15-minute burn-off after conversion to purge air and seat components.

Performance Optimization Post-Conversion

Your upgraded grill demands new habits. Preheat to 800°F for searing (2-3 minutes). Use zoning: Infrared for proteins, traditional zones for sides. Maintain by brushing emitters gently—avoid water quenching hot ceramics.

• Cleaning: Vacuum ash weekly; replace emitters yearly.
• Fuel Savings: NG conversions cut costs 30-50% vs. LP tanks.
• Recipe Tweaks: Reduce times 20-30%; flip once for crust.

Benefits of Infrared Over Traditional Grilling

Beyond aesthetics, infrared delivers measurable gains: Juicier meats (retained moisture up to 20% more), flare-up resistance via radiant focus, and versatility for pizza or wok cooking. It’s a worthwhile investment for enthusiasts seeking pro-level results.

Frequently Asked Questions (FAQs)

What if my grill lacks a conversion kit?

Source one from the manufacturer matching your model; universal kits risk incompatibility.

Can I convert back to standard burners?

Yes, reverse orifices and regulator, but infrared plates stay for hybrid use.

Is infrared safe for everyday family grilling?

Absolutely, with proper setup—intense but controlled heat prevents charring.

How long does conversion take?

1-2 hours for experienced users; allocate 3-4 for beginners.

Does warranty void on conversion?

Manufacturer kits preserve it; DIY with non-approved parts may not.