Introduction
A summer cookout should be simple. Yet many grill owners end up juggling small propane bottles, hunting for refills at the worst moment, or wondering whether the richer taste of charcoal is worth the extra effort. If you have asked yourself whether there is a better, cheaper, or safer way to fuel your grill, you are not alone.
Most backyard grills can move from propane to natural gas—or even welcome charcoal—when the right kit, clear safety steps, and up-to-date local rules line up.
Shifting fuels is not one choice; it is a series of linked decisions. Before drilling a hole in metal or ordering a conversion hose, you need clear answers about parts, safety, cost, and long-term value. The next sections walk through the most common questions in the same order most grill owners ask them.
Is my propane grill compatible with natural gas conversion kits?
Your grill’s nameplate is the first clue. It lists model, BTU rating, regulator type, and sometimes a “convertible” note. Most mid- to high-range grills sold after 2010 use threaded brass orifices that you can swap, but many budget grills either weld jets in place or lack room for a natural-gas regulator. Check for threaded jets and a removable hose before you buy any kit.
Key points to confirm
| Item on nameplate | Sign it fits natural gas | Action if missing |
|---|---|---|
| “Convertible” label | Yes | Buy matching NG kit |
| Jet size code | Yes | Order exact NG orifice |
| Max pressure PSI | 4–7 in. W.C. | Ask a plumber |
If your model is Canadian or American, its manual often shows an optional part number for the natural-gas valve. Brands like Weber, Napoleon, and Broil King publish clear “yes/no” charts online. European grills follow CE markings and usually need factory service instead of DIY. Older grills without a flexible hose often have steel lines fused to the manifold; those are rarely worth altering. Measure the burner tube diameter, count burner rows, and compare them with kit specs. If each burner gets the right cubic-foot-per-hour flow after jet swap, flame height stays safe. Failing to match jets starves the flame or overheats parts. A long look now means fewer surprises later. Owners who skip this step end up chasing stray leaks or weak flames, wasting time and gas. Write down all nameplate data before shopping; it speeds every call with support staff.
Which conversion kit best suits my grill brand and size?
You can buy universal kits or brand-specific sets. Universal kits ship with a group of jets sized from roughly #54 to #60 and a generic 10-foot hose. Brand kits cost more but include color-coded jets, a pre-set NG regulator, and fitting sizes that drop into your manifold without thread tape. Choose a kit sold or approved by your grill’s maker to keep thread fit exact and warranty in place.
Quick kit comparison
| Feature | Universal kit | Brand kit |
|---|---|---|
| Price | Lower | Higher |
| Fit risk | Medium | Low |
| Warranty impact | Often void | Usually safe |
Universal kits help when a brand is out of stock, yet they force you to size the jet by hand. You will need a pin gauge or drill bits to match orifice diameters, then mark each jet so you do not mix them up later. A kit with the wrong thread pitch may cross-thread in soft brass; once that happens, gas can leak at start-up. Brand sets avoid that problem. They also ship with step-by-step photos, saving guesswork. For grills over 60 000 BTU, insist on a kit with at least a 3/8-inch inside-diameter hose to avoid pressure drop. If your grill uses side burners or sear stations, check that the kit lists extra orifices for those zones. Finally, look for CSA or UL marks on hoses; they certify burst strength and flame-resistant jacket material.
Will switching fuels void my existing grill warranty?
Most U.S. and Canadian makers cover rust, burn-through, and paint for five to fifteen years, but they split fuel parts into a shorter window. Weber and Char-Broil state that any field conversion voids coverage on gas parts unless done with their own kit. Use an approved kit and keep your purchase receipt to preserve warranty on burners and valves.
Typical warranty language
| Brand | DIY conversion covered? | Parts still protected |
|---|---|---|
| Weber | Only with Weber kit | Lid, cookbox |
| Napoleon | Only with official kit | Stainless body |
| Generic import | Never | None |
Scan the fine print. Some brands let a licensed gas fitter complete the work without voiding coverage, even if you ordered a third-party kit. Photograph each step so you can show proper install if a claim comes later. Keep original propane parts in a labeled bag. If you ever move and need to revert to cylinders, you will have the correct pieces. Note: if the change adds a charcoal tray, warranty on burners may stay but warranty on flavorizer bars may not. Each company draws its own line.
What essential safety checks precede any propane-to-natural gas conversion?
Safety starts with three moves. First, shut the propane valve, then open the burners to bleed gas. Second, remove the cylinder and store it outdoors upright. Third, run a soap-and-water test on every new joint after install. A leak test with soapy water at 10 PSI air pressure finds pin holes before you light a burner.
Safety checklist
| Step | Tool | Pass sign |
|---|---|---|
| Bleed lines | Grill knob | No hiss heard |
| Jet removal | Box wrench | Threads clean |
| Leak test | Soap brush | No bubbles |
Use a soft brass brush to sweep threads, not steel; brass keeps sparks away. Wrap yellow PTFE tape rated for gas, never white water-line tape. Torque fittings hand-tight plus one quarter turn. After leak test, fire each burner for one minute. Flames should be blue with a short yellow tip. A tall yellow flame marks low pressure or clogged jets. Keep a fire extinguisher rated for grease fires within reach, not a water hose.
How much money could natural gas save over propane annually?
Propane in the U.S. averages about $4 per gallon in peak summer. A gallon holds roughly 92 000 BTU. Natural gas averages $1.70 per therm (100 000 BTU). When you burn 20 000 BTU per hour for three hours each week, a season needs about 3 million BTU. At those rates, propane costs near $130 a season while natural gas costs near $51, saving about $79 each year.
Cost math at a glance
| Fuel | Cost unit | BTU per unit | Season price* |
|---|---|---|---|
| Propane | $4 / gal | 92 000 | $130 |
| Natural gas | $1.70 / therm | 100 000 | $51 |
| *Assumes 150 hours grilling at 20 000 BTU/h |
Savings rise if you grill longer or at higher heat. Large four-burner grills often pull 40 000 BTU at high, doubling the gap. Over five years, the extra cost of a conversion kit and gas hookup—usually $250 to $400—pays for itself. In regions with cold winters, propane price spikes widen the spread. Natural gas bills arrive monthly, smoothing cash flow. Propane tanks still help during power outages; many owners store one spare for emergency heating.
Should I attempt conversion myself or hire a certified technician?
A handy owner can swap jets in thirty minutes, yet routing a rigid iron pipe under patios, setting a shutoff valve above grade, and pressure-testing the line often require a licensed fitter under building code. Hire a technician if local code asks for an inspection tag or if you lack gas-rated tools.
Task split guide
| Job | DIY friendly? | Pro needed? |
|---|---|---|
| Swap jets | Yes | No |
| Replace regulator | Yes | No |
| Run buried pipe | No | Yes |
| Pull permit | No | Yes |
A pro brings thread sealant rated for gas, a manometer to set pressure, and liability coverage. Labor runs $75–$150 an hour; most conversions need two hours. DIY saves money but carries risk. If you smell gas after install, turn off the main valve and call the utility. Never bury flexible hose; code calls for iron or copper under soil. Document the route on a sketch so future digs miss the pipe.
How do I safely route a backyard natural gas line?
You begin at the meter’s existing tee or install a new one. Local code often says bury black iron or polyethylene pipe at least 18 inches deep. Add a trench marker tape six inches above the pipe. Place a shutoff valve within six feet of the grill, mount it 12 inches above grade, and secure hose with a quick-disconnect fitting.
Routing tips
| Rule | Depth | Reason |
|---|---|---|
| Frost line + 6 in. | 18–24 in. | Avoid freeze |
| 12-in. rise | Valve height | Easy access |
| 3 ft. from electric | Spacing | Spark safety |
Before digging, call 811 in the U.S. to mark utilities. Lay sand under pipe to cushion rocks. Coat iron pipe with approved primer or wrap with tape to resist rust. Where pipe meets patio, add a drip leg to catch debris. End the run with a stainless steel flex hose rated at max 0.5 PSI. Attach the quick-disconnect so you can pull the grill in winter.
Does natural gas affect grilling temperature or searing performance?
Natural gas holds less energy per volume than propane—about 1 012 BTU per cubic foot versus 2 516 for propane vapor. The grill compensates by pumping a larger gas volume through bigger jets. With the right jets, natural gas reaches the same 600 °F searing zone as propane, but preheat time may run two minutes longer.
Flame facts
| Fuel | BTU per ft³ | Jet drill size* |
|---|---|---|
| Propane | 2 516 | #54 |
| Natural gas | 1 012 | #45 |
| *Typical for 12 000 BTU burner |
Searing tests on cast-iron grates show steak surface browning equal after six minutes per side on both fuels. The main trick is keeping the lid down during warm-up so heat does not vent. Many owners mistake lazy yellow flames for low heat, but that color signals wrong air mix, not weak fuel. Open the air shutter under the burner until flame tips turn blue.
Is a hybrid gas-charcoal setup the best of both worlds?
Hybrid grills let you keep the steady heat of gas while adding smoke flavor when you want it. A charcoal tray fits above burners; you light briquettes with gas, shut the gas valve, then cook on glowing coals. A hybrid saves start-up time and halves charcoal use because you skip chimney lighting.
Hybrid pros and cons
| Factor | Hybrid | Pure charcoal |
|---|---|---|
| Start time | 10 min. | 25 min. |
| Fuel cost | Mid | Low |
| Flavor | Good | Best |
A hybrid tray lifts the charcoal bed closer to food, reducing flare-ups. Grease falls on coals and vaporizes, adding smoke. Some trays let ash drop through slots so burners stay clean. Drawback: you still sweep ash after every long cook. At high heat, the metal tray can warp; choose 304 stainless if possible. If your grill has infrared plates, check clearances before adding a tray so it does not block gas ports.
How to add a charcoal tray inside a standard gas grill?
Measure your firebox width and depth, then buy a tray two inches narrower so air flows around it. Remove cooking grates, place the tray on burner shields, load it one layer deep with lump charcoal or briquettes, and open the gas burner under it for five minutes. When the coals gray over, shut the gas valve and reinstall grates to cook.
Tray placement steps
| Step | Time | Tip |
|---|---|---|
| Measure box | 1 min. | Leave 2-in. gap |
| Insert tray | 1 min. | Level surface |
| Light with gas | 5 min. | Lid closed |
Keep vents half open so coals breathe. After cooking, close lid and vents to suffocate coals; this saves them for later. Empty ash only after metal cools. Never dump ash in plastic bins; embers can smolder for hours.
Will natural gas lower my grill’s environmental footprint compared to propane?
Natural gas emits about 117 pounds of CO₂ per million BTU burned; propane emits roughly 139 pounds. That gap slices carbon output by around 16 %. Switching a 3-million-BTU season from propane to natural gas cuts close to 66 pounds of CO₂—equal to driving a sedan about 75 miles.
Emission data
| Metric | Propane | Natural gas |
|---|---|---|
| CO₂ lb / MMBTU | 139 | 117 |
| Season CO₂ lb | 417 | 351 |
Natural gas supply lines avoid the trucking and steel cylinder production tied to propane. Yet methane leaks in gas pipelines offset some gains. Still, for most urban homes, the net footprint declines. Charcoal has the highest CO₂ per meal unless you use sustainably made lump wood and burn it hot and fast. A hybrid approach—gas for weekday meals, charcoal for special cookouts—balances taste and emissions.
When is replacing an old grill smarter than converting fuels?
Grills rust from the inside out. If burner tubes flake, flavorizer bars warp, or the lid no longer seals, a conversion will not give long life. Replace a grill when repair costs reach half the price of a new, factory-ready natural-gas model with fresh warranty.
Replacement clues
| Symptom | Fix cost | Replace? |
|---|---|---|
| Burners rusted | $80 | Maybe |
| Firebox cracked | $150 | Yes |
| Lid enamel peeling | Cosmetic | No |
New natural-gas grills ship with sealed manifolds and quick-connect hoses. They often add upgraded grates and side burners. Over a ten-year span, you save on parts plus fuel. Factor resale, too: a solid NG grill fetches more on local listings than a converted older propane model with extra holes drilled in it.
Conclusion
A fuel swap looks simple—just a new hose, right? In truth it calls for the right kit, a leak-tight install, and clear knowledge of cost, heat, and warranty. Start by reading your nameplate and manual. Choose a maker-approved kit. Run a strict leak test. Weigh long-term savings and lower carbon output against upfront parts and labor. If your grill is sturdy, conversion pays back fast and keeps the sizzle all season. If it is tired, step up to a new natural-gas or hybrid model and enjoy reliable heat, fewer refill runs, and steaks that sear right every time.