How to Restore an Old Kamado Grill

Kamado grills are legendary for their durability and classic design. Whether you’ve lucked out at a garage sale, inherited a backyard relic, or just want to give your longtime grill a second life, restoring an old Kamado is one of the most rewarding DIY barbecue projects around. Here at Vessils, we’re proud to build what we believe are the best kamado grills available today—but we also celebrate the excitement and nostalgia of bringing an older kamado, from any brand, back to its former glory.

This step-by-step guide is packed with practical restoration tips and expert advice. Throughout, we’ll reference helpful tools, parts, and accessories from our own lineup. While Vessils grill parts are specifically engineered for our models, some might also fit traditional or vintage kamado grills—so feel free to browse our Grill Parts & Accessories Collection to see if there’s a solution that matches your restoration needs.

Step 1: Carefully Assess Your Kamado Grill

The first step in any successful kamado grill restoration is a thorough inspection. Examine your grill for:

• Cracks or chips in the ceramic body or dome

• Worn, missing, or dried-out gaskets

• Rust or corrosion on metal bands, hardware, or hinges

• Damage or wear inside the firebox and fire ring

• Grease buildup, caked-on food, or excessive ash

This assessment helps you pinpoint what to clean, repair, or replace. Need new gaskets, bands, or panels? Take measurements and check our kamado grill replacement parts for possible fits.

Step 2: Disassemble for Deep Cleaning and Inspection

Remove the cooking grate, firebox, fire ring, and ash drawer (if equipped). Keep all screws and small hardware organized for easy reassembly. Having the right grill tools helps—try a Grate Lifter – Vessils Grill Tool to safely and efficiently access all components.

Step 3: Clean the Interior and Exterior

Restoration starts with a fresh canvas. For the interior, vacuum or scoop out all ash using an Ash Tool; then, gently scrub away stubborn debris with a plastic scraper or grill brush. Use warm soapy water for a final wipe-down, but avoid saturating the ceramic.

For the exterior, wipe off dirt and grime with mild soap and water, and skip abrasive or solvent-based cleaners. For more advice, read our guide on how to properly dispose of ash after grilling.

Step 4: Repair or Replace Damaged Parts

Most heat loss or flavor issues in kamado grilling come down to worn-out or poorly fitting parts. Here’s what to address:

• Replace old gaskets with a high-degree heat resistant gasket kit. While ours are tailored for Vessils grills, sizes may fit classic models—just confirm the measurements.

• For fire rings or fireboxes, patch minor cracks with high-heat ceramic cement or consider a replacement from our ceramic fire box panels collection if compatible.

• For rusted bands or hinges, clean and repaint with high-temp paint or explore upgrades in our kamado hardware collection.

• Explore charcoal plates  that may boost fuel efficiency and heat distribution—even in older grills, depending on sizing.

If you’re unsure about fit, consult our product info or contact our support team with your grill’s dimensions—we’re happy to help you find a match if possible.

Step 5: Thoughtful Reassembly

Once cleaned and repaired, reassemble your kamado grill. Align bands evenly, tighten bolts just enough for security, and don’t over-torque, as too much pressure can risk cracking the ceramic. If you’re adding accessories, now’s the time to install them.

Step 6: Reseason Your Kamado Grill

After major cleaning or repairs, it’s wise to reseason your kamado to remove any lingering odors and renew the interior. Light a small charcoal fire (see our guide to the best charcoal for smoking), gradually raise the temperature to 400°F, and hold it there for about 30 minutes. Let the grill cool completely with the lid closed.

Step 7: Ongoing Kamado Grill Maintenance

A restored kamado can last for decades with the right care. After each cook, clear out ash, wipe surfaces clean, monitor gasket condition, and protect your grill with a heavy-duty kamado grill cover to prevent weather damage. For continued insights, don’t miss common charcoal smoking mistakes beginners make and our articles on kamado grill maintenance.

Important Note on Compatibility

Because kamado grills come in different shapes and sizes, our Vessils grill replacement parts and accessories are guaranteed for Vessils models only. However, many restorers have successfully adapted our products for older or traditional kamados—especially universal-style tools, gaskets, and some firebox components. Always check your measurements and installation needs before ordering, and feel free to reach out to our support team if you have questions about compatibility. We’re here to help every barbecue lover, whatever brand you’re restoring!

Final Thoughts on Restoring Kamado Grills

Restoring an old kamado grill is about more than appearances—it’s about reclaiming performance, savoring classic wood-fired flavors, and honoring barbecue tradition. While we’re proud that Vessils sets today’s gold standard for quality, we love seeing enthusiasts breathe new life into any kamado. With a little effort and the right parts, your grill—no matter its age—can deliver sizzling meals for years to come.

Ready to continue your grilling adventure? Explore our complete Grill Parts & Accessories Collection or browse all Vessils Kamado Grills to find the best fit for your backyard journey.