First, cut four short pieces of angled aluminum stock or some of the other type metals that are available such as angle iron would be ideal. Just be sure not to use galvanized metal for these new brackets. Galvanized metals produce toxic, noxious fumes when heated and would certainly permeate your foods.
Simply cut 4 brackets, they do not need to be very long, essentially what you are doing is making shelves for a cut piece of expanded metal to sit upon.
The brackets should be mounted approximately four inches below the where the grill grate sits. They need to be at the least 3.5"-4" below your grill grate for this modification to work properly. (enlarge above photo for details) Any closer and you could risk cooking your food a little too fast. You will understand what i mean by this as you progress down this posting.
You can easily drill through the grill housing with any sharp bits without injury to the grill, it is an aluminum alloy type material and drills very easily. I used self tapping screws to drill directly into the bracket, thus i used no nuts.
A little closer view of these brackets added for the implementation of the lower grate which will be installed.
Next, add a gas grill expandable burner cover. These can be bought from wal-mart or some of the online stores.
If you will take notice, I actually installed my brackets to coincide with the apex of the burner cover for two reasons:
First, you want the secondary grate that will be installed to be at the least 3-4" below your cooking grate.
Second, it provides a center-line support element for the secondary grate when installed.
Install a piece of expanded metal that sits upon these newly installed brackets. I would suggest purchasing your expanded metal from a local welder in your area for it is overly expensive if bought from one of the big box stores. Plus, they have the equipment to cut this stuff to your precise measurements.
Next you will need briquettes that are designed for use in gas grills, one bag is sufficient. I purchased mine from Wal-Mart.
Next line the briquettes up on the expanded metal so that there are not any holes located within them. This prevents any flames from protruding upwards. I like to over lap them a little whenever i put new briquettes in my grill. As you can notice these have been used for a while. By the way, they last for several years before needing replacing.
Don't worry, the drippings on the briquettes only serve to flavor foods cooked in the future...no need to clean them off after cooking unless you want to.
I had cleaned my grill today and thought i would share with others, this idea of how i solved my gas grill flare ups forever. Thus the reasoning behind the really seasoned briquettes. Your new ones will look like those in the lower right corner of the grill- typically gray in color.
Now you have a gas grill that will serve you well and with this modification will eliminate all flare ups for good.
If you have found this post useful, please consider donating.