What caused this rust?

[BBQandLove]

The handle on my ash catcher on my 70th anniversary rusted almost immediately.

I’m not worried about it. I can either take care of it myself or contact Weber and they will send me a new one. But I’m really intrigued by the question of why this happened.

No chemicals touched this one. Other Kettles are all around it, some three and four years old with no problems. I have used harsh chemicals on the other ones, again with no problems.

I asked about this on a certain Facebook page, but just when the conversation was getting good, an admin decided that it wasn’t something we should be discussing. So I thought I’d bring it here, and see what you guys think.

Some thought that the handle was contaminated before it was coated at the factory. That makes some sense to me.

Again, I’m not asking what to do about, it nor am I perturbed that it happened. I’m just intrigued about the why.

[rlozinak]

For the price of that grill I would be upset

[BBQandLove]

I’m not. Flaws happen.

[Spinaker]

Ash is corrosive. Contact points like this can cause rust easily. Especially when combined with moisture and the elements outside

That being said, it shouldn’t be happening on a unit this new.

[MsTwiggy]

That's disappointing, but I'm sure weber would make it right.

[jfmorris]

That looks like it is nickel plated steel, not stainless, but it is still surprising it did this so soon. I’ve got a 15 year old Performer Deluxe and do not think my handle looks like that.

Let us know what Weber does about it.

[smokenoob]

rust never sleeps 🙄

[Mosca]

Live Rust for the win.

[troymeister]

I'll bet you came up with that out of the blue.

[smokenoob]

troymeister came right from a horse’s mouth….

[HawkerXP]

None of these are stainless. 10-year warranty on all metal parts.

I would suspect poor prep before plating. Anyone know of an aftermarket manufacturer of these?
Weber doesn't, to my knowledge, sell just the handle.

[LA Pork Butt]

In my memory bank I think the original Weber company was sold recently. I would bet on an new manufacturing process designed to cut costs. If other 70th anniversary edition purchases report the same thing I would be leaning there. Otherwise it is just a strange anomaly.

[Steve R.]

I wouldn't be so sure that Weber will do anything. I had an issue with my 26" kettle where there was a small rusty spot inside the bowl where the ash sweeper was making contact with a slightly raised spot where the leg socket is spot welded on the outside. I was told by customer service that the warranty only covers rusted-through parts, not surface rust.

I then took a cloer look and saw that two of the three tabs of the leg socket weren't even welded onto the bowl. I contacted CS again with pics of that and they promptly sent a new bowl. The welding sucked even worse on the replacement, but that's another thread.

[LA Pork Butt]

In 2012 their warranty and customer was great. Like with most buyouts, profit is the only driving force. They will be able to live only so long off of the Weber reputation.

[captainlee]

Poor prep before plating the metal.

[bbqLuv]

For the Rust the handle not bright
For Rust it seems to be faster than light
For Rust to be removed with vigor and might
For Rust reappeared the previous night

[Uncle Bob]

Even if you don't give a rip about it for you, I'd still suggest you contact Weber and let them know. One of the frustrations I had as a business owner was when people DIDN'T complain when they had a legitimate issue. How could I fix a problem, if there was one, if I wasn't made aware of it. Don't assume they know................

[N227GB]

This. Most likely there was a contaminant not removed completely during the plating process. Ironically, it may have been a coating to prevent rust while the metal was bare. If they're on the ball when they receive your warranty claim this will initiate a root cause analysis within the production team.

[Dr J]

I think it was a flaw at the factory. I would contact Webber and let them make it right since they have a 10 year warranty.

[smokenoob]

agree! poor plating

[RiverJeff]

I think all these company are going to chrome power coating for fast and cheaper finishes then when piled up at assemble site they bang around one other and get damaged ending up in water access to metal and rust.
Call them on it! so they are aware of the problems!