How to Replace a Built-In Grill in the Same Cutout: Measuring, Jackets and Trim

Replacing a built-in grill is one of the most common jobs we quote, and the question is always the same: what will fit the hole I already have? The answer depends on three measurements and one question about how your island was built. Get those right and you can usually drop in a new grill without cutting stone. Get them wrong and you're paying a mason.

Why grills that look the same size don't fit the same hole

A "32 inch grill" describes the grill, not the opening. Each brand sets its own cutout, and they differ by more than you'd think. Real numbers from manufacturer specs:

• Blaze Premium LTE 32: about 30 5/8 W x 21 1/4 D x 8 1/2 H
• Summerset Sizzler 32: about 30 5/8 W x 20 3/4 D x 8 H
• Lion L75000 32: about 31 W x 21 1/2 D x 9 5/8 H
• Lynx Professional 36: about 35 W x 22 D x 10 7/8 H
• Alfresco ALXE 36: about 34 1/2 W x 23 D x 10 1/4 H
• Twin Eagles 36: about 34 1/4 W x 24 1/4 D x 11 3/4 H

The height and depth vary the most. A Twin Eagles needs almost four inches more height than a Summerset. Brands also change cutouts between model generations, so always check the current install manual for the exact model.

How to measure your cutout: A, B and C

Pull the old grill out if you can. Measure the opening itself, not the old grill.

1. A, width: measure side to side across the opening at the front and at the back. Use the smaller number.
2. B, depth: measure from the front edge of the countertop to the back wall of the opening. Check left and right sides.
3. C, height: measure from the floor of the opening (the surface the grill sits on) up to the top of the countertop. Check front and back, since some islands slope for drainage.

Write down all six readings in inches to the nearest 1/8. Note where the gas line comes in, any shutoff valve, outlets or ribs that stick into the opening, and whether there's a lip of stone or tile that overhangs the edges.

Then plug A, B and C into the Pro Grill fit guide. It shows which grills fit your opening and how close each one is in width, depth and height.

Insulated jackets: check this before you buy

An insulated jacket is a stainless sleeve that sits between the grill and the island. Manufacturers require one when the island is framed with wood or steel studs or has combustible material near the grill. Many older islands in California and Arizona were built without one.

A jacket needs a bigger opening than the grill alone. For example, Blaze's 32 inch grill needs about 30 5/8 x 21 1/4 x 8 1/2, but its insulated jacket needs about 33 inches wide and around 9 3/4 inches tall, with depth closer to 22 inches. If your current opening was cut for a jacket, you have more room to work with. If you're adding a jacket now, you may need a larger cutout.

The cutout fit guide has a setting for insulated jackets so you can compare openings either way.

What makes a grill fit, or not

From what we see on installs:

• Width is the hardest to fix. A grill can't be narrower than the hole with gaps on the sides, because the grill's side lips or the countertop hold it up. Trim strips don't support weight. Widening an opening means cutting stone and sometimes block.
• Too little height is the hardest change. Lowering the floor of the opening usually means rebuilding the support inside the island.
• Extra depth is the easiest. A grill that's shallower than the opening can often be filled in at the back with a stainless trim piece or filler.
• Extra height can sometimes be shimmed or filled with trim, as long as the grill is solidly supported.
• Going to a much smaller grill is almost never a good idea. You'd need new framing to support it, and filling a big gap with trim looks bad and doesn't hold weight.

Trim kits and filler strips

Several brands sell trim kits or filler panels to close small gaps around a replacement grill. They help with a slightly deep or tall opening, and can clean up an edge where an old grill sat. They are cosmetic. Never use trim as the thing holding the grill up. If the gap is more than about an inch, have a pro look at it.

Gas, power and venting

A replacement grill may have its gas inlet in a different spot than the old one, so the flex line may need to be rerouted. Check the fuel type, since natural gas and propane grills are not interchangeable without a kit. If the new grill has lights or electronic ignition, you'll need a GFCI outlet in the island. Make sure the island still has ventilation openings, which are required for gas grills and especially for propane.

Any gas line changes should be done by a qualified pro, with a leak test on every fitting afterward.

Should you repair the old grill instead?

If the old grill's body and firebox are solid, new burners, valves or ignition might give it years more life for much less than a new grill plus install. Our repair or replace cost guide walks through the math. Parts for many brands are in the Pro Grill store, and you can ask Pro Grill to find a part that isn't listed. Brand guides like Lynx parts prices and Fire Magic parts prices give you a quick sense of cost.

Get it done right

Measure, run it through the grill fit tool, then compare brands in our built-in grill brands by budget guide. For installation, look up typical grill installation costs and find a grill installation pro. Most companies in our network are dealers or have dealer accounts, so they can order the right grill and jacket and install them in one visit. If you'd rather start with a local pro, search by ZIP code.

Frequently asked questions