How to Convert a Propane Grill to Natural Gas

Switching your propane BBQ grill to natural gas offers long-term savings, unlimited fuel supply, and hassle-free operation without tank refills. This detailed guide outlines the entire process using manufacturer-approved methods, ensuring safety and performance. Natural gas burns cleaner and more efficiently for propane setups after proper adjustments, primarily involving orifice swaps and hose connections.

Why Make the Switch to Natural Gas?

Natural gas provides a steady, on-demand fuel source directly from your home line, eliminating the need for bulky propane tanks. Users report up to 50% lower fuel costs over time, with no interruptions from empty tanks during cookouts. However, success depends on local natural gas availability and grill compatibility—most modern propane models from brands like Weber or Char-Broil support conversions via kits.

Key benefits include environmental advantages, as natural gas emits fewer pollutants than propane combustion. It’s ideal for frequent grillers who value convenience. Before starting, confirm your grill model has an official conversion kit; generic kits risk improper sizing.

Essential Tools and Materials

Gather these items for a smooth conversion:

• Manufacturer-specific natural gas conversion kit (orifices, hose, regulator)
• Adjustable wrench or nut driver set (sizes #6 common)
• Needle-nose pliers for cotter pins
• Phillips and flathead screwdrivers
• Pipe thread sealant (gas-rated, non-hardening)
• Soap-water solution for leak testing
• Safety gloves and eye protection

Without the kit, custom drilling orifices is possible but risky—propane orifices are smaller (higher pressure), while natural gas requires larger ones for lower pressure flow. Drilling enlarges holes irreversibly, committing you to natural gas only.

Preparation Steps: Safety First

Turn off all grill knobs and disconnect any propane tank completely. Remove it from the area. Open the grill lid to ventilate. Work in a well-lit outdoor space away from flames or sparks. Shut off your home’s natural gas supply at the meter if routing new lines.

Inspect your grill for damage: rusted burners or valves may not suit conversion. Document your model number for kit verification. Local codes often require professional hookup for the gas line—check municipal regulations to avoid fines.

Detailed Disassembly Process

Begin by accessing internal components:

1. Lift out warming racks, grates, and heat diffusers/flame tamers for clear access.
2. Locate burner hitch pins or cotter pins at the rear—use pliers to remove them carefully.
3. Slide burners upward and forward to detach from valve orifices. Label each for reassembly.
4. For rear infrared or rotisserie burners, unscrew access panels with a Phillips screwdriver.

This exposes the brass orifices—small jets threading into valves. Propane versions have tiny holes (#53 drill bit size approximates natural gas needs, but kits provide exact matches).

Replacing the Orifices

Orifices control gas flow: propane’s high pressure needs small apertures; natural gas’s low pressure demands larger ones.

Use the kit’s removal tool or nut driver to unscrew old orifices counterclockwise—save them for potential reversal. Insert new natural gas orifices hand-tight, then snug with a wrench. Avoid over-tightening to prevent thread damage. Repeat for all burners, including side and rear units. Valves on propane grills often handle natural gas post-orifice swap without issues.

Regulator and Hose Installation

Disconnect the propane regulator/hose from the manifold (usually rear or under shelf). Some grills have adjustable regulators with flip plungers marked LP/NG—unscrew, reverse, and reinstall for gas type orientation.

Route the new natural gas hose (often flexible stainless) from your home line to the manifold. Secure with fittings and sealant. If no kit hose, use an appliance regulator matching natural gas specs. Connect to a shutoff valve on your gas line for easy isolation.

Reassembly and Testing

Reverse disassembly: reinsert burners over valves (ports up), secure with pins, replace tubes/brackets, and reinstall grates. Check bezels/knobs if kit includes NG versions for alignment.

Leak test: mix dish soap/water, apply to connections, slowly open gas supply. Bubbles indicate leaks—tighten or reseal. Ignite burners on low, adjusting for even blue flames (yellow means improper mix). Start high, then fine-tune air shutters for efficiency.

Safety Precautions and Common Pitfalls

Never convert without a kit unless professionally drilled—mismatched orifices cause weak flames or explosions. Natural gas-only after enlargement; propane reverts need new small orifices.

• Prohibit indoor work: Gas is heavier than air; leaks pool dangerously.
• Verify BTU ratings: Ensure total output matches (e.g., 38,000 BTU grill needs scaled orifices).
• Professional final hookups: Gas line plumbing requires certified techs in most areas.
• Post-conversion monitoring: Watch for corrosion or uneven burning first 10 uses.

Errors like over-drilling yield low flames (as in Weber Genesis cases); under-sizing risks flare-ups.

Troubleshooting After Conversion

Weak flames? Check orifice seating, air shutters, or pressure (should be 5-7″ WC). Clean burners.
No ignition? Verify gas flow, spark module.
Uneven heat? Realign carryover tubes.
If issues persist, revert to propane temporarily using saved parts.

Cost Analysis and Long-Term Value

Kits cost $50-150; pro install adds $200-500. Savings: natural gas ~$0.50/hour vs. propane $1.50. Payback in 1-2 seasons for heavy users. Enhances home value with permanent setup.

FAQs

Can any propane grill convert?
Most post-2000 models yes, with kits. Pre-1990s may lack compatible valves.

Is DIY legal?
Orifice/hose swaps often DIY, but gas line connections need licensed plumbers per code.

How long does it take?
2-4 hours for experienced users; double for novices.

Reversible?
Yes, if orifices saved and not drilled.

Side burner conversion?
Separate orifice usually; kit-specific.

Advanced Tips for Optimal Performance

Upgrade to high-BTU natural gas lines for searing power. Install a quick-connect swivel for mobility. Annual checks prevent methane leaks. Pair with smart igniters for modern appeal.

This upgrade transforms seasonal grilling into year-round enjoyment. Always prioritize safety—consult manuals and pros.