How to Choose the Right Grill Cover: Material, Size, and Features
Carly Vicknair - Senior Marketing Specialist, Coverstore
Carly is a Senior Marketing Specialist who brings product expertise and real customer insight to her writing on outdoor living and cover care.
Grill cover material is the single biggest predictor of how long a cover lasts, and it is the thing most shoppers skip past. Finding the right cover can be challenging when the market has not caught on to new grill models or kept up with older grill designs. Even if your grill came with a cover, most only last a season or two before they are full of holes or lost to the wind.
This guide walks through every essential aspect of buying a new grill cover, or bbq cover if that is what you call it, starting with the material, so your grill stays protected all year long.
Why a Grill Cover Matters
Beyond the fact that grills are a costly investment, they feed you and the people you love. That earns them being kept clean and protected so they keep looking and working their best. Coming outside to find your gas grill, built-in grill, or any other variety covered in dirt, rust, or filled with water puts a quick halt on your plans. Considering the time and money an easy to use cover saves, the question is really why you would not cover your grill.
5 Questions to Answer While Cover Shopping
- What is the right grill cover material for my climate?
- What style of cover is right for my grill?
- How do I find the right size, and would a custom size be better?
- What features should I look for?
- How do I know which cover offers the best value?
Grill Cover Material: What Actually Lasts
Most covers sold in big box retailers are made of low quality vinyl and do not perform well in heavy sun. Average vinyl has a short lifespan, and you will find yourself replacing it constantly. When picking a quality cover, look for thick, durable polyester that stands up to a range of weather. Unlike vinyl, polyester will not crack or peel in extreme heat or cold.
The clearest sign of reliable, heavy duty polyester is its weight, referred to as denier. Heavy duty grill covers start at 600 denier, so look for that number or higher. If a manufacturer does not publish that number, it is worth calling to confirm, so you do not end up with a low quality cover by mistake.
Grill Cover Material Compared
| Material | Strengths | Watch Out For |
|---|---|---|
| Polyester, 600 denier or higher | Durable, fade resistant, will not crack in heat or cold, widest color range. This is what heavy duty grill covers are made from | Denier below 600 gives up most of the durability |
| Commercial grade vinyl with lining | Cost efficient, easy to wipe clean | Stiffens in cold, shorter lifespan in strong sun |
| Canvas | Breathable and sturdy, canvas grill covers resist tearing well | Heavier to handle, and untreated canvas absorbs water |
| Thin unlined vinyl | Cheapest option available | Cracks and peels, usually the covers that fail in a season |
Why Polyester Wins for Most Grills
- Durable
- Fade resistant
- Crack resistant
- Water resistant
- Long lasting
- More color options
One thing worth being precise about: if you are searching for a waterproof grill cover, water resistant is actually what you want. A fully sealed cover traps condensation underneath and creates the mildew it was meant to prevent. Our article on why waterproof covers are a myth covers the tradeoff in depth.
Grill Cover 101
Video Summary
A primer on what separates one grill cover from another, covering the material and construction differences, the features that keep a cover secure, and how to match a cover to your grill.
Types of Grill Covers
The next step is identifying the type of grill you have. If you are already familiar with grills this goes without saying, but if you are new to it, or about to buy, check the manufacturer's information first. Each style has its own features and build, from cart grills to island grills. Some styles look very similar while their corresponding covers vary in ways that matter.
- Cart grill
- Island grill
- Built-in grill
- Kamado grill
- Smoker
- Kettle grill
- Flat top grill
How to Find the Right Size Grill Cover
Measuring correctly is essential to getting a cover that performs. A cover that is too small obviously will not fit, but an oversized one has its own drawbacks. Excess fabric creates pockets that collect water, which leads to mildew growth and moisture seeping through the fabric.
Knowing how to measure a grill for a cover takes three numbers: width at the widest point including side shelves, depth front to back, and height from the ground to the top of the closed lid. Record everything in inches and measure twice. If you cannot find the manufacturer's exact dimensions, follow our guide on how to measure for a grill cover.
Grill cover sizes are usually listed by those same three dimensions rather than by a size label, bbq cover sizing included, so once you have your numbers you can shop by measurement instead of guessing at small, medium, or large.
Custom Grill Covers vs Standard Sizes
Standard size covers suit customers who need a cover as quickly as possible and have a grill that fits preset sizes. Finding an adequate size gets much harder with older grills, which tend to be larger than today's models, and with custom grills, which are becoming more common.
Custom sizing also benefits common grill designs by giving a more form fitted look. That improves the aesthetic and boosts performance by minimizing sagging. Custom covers open up more options across colors, materials, and grill types too. Whether you have a gas grill, a flat top, or a custom built island, a custom size grill cover keeps the investment protected, with a step by step measuring guide and no long lead times.
Custom Cover Benefits
- More color options
- Better fit
- Boost to performance
- Short lead times
- Various grill types
Standard Cover Benefits
- Ready to ship
- Various size options
- Adequate fit
Features Your Grill Cover Needs
Every cover comes with its own set of features, and you may wonder whether the bells and whistles are worth the money. A few genuinely change how easy the cover is to live with.
Air vents are the most overlooked and the most necessary. They allow airflow, which releases excess moisture from under the cover, and they are what makes it safe to cover a grill that has cooled but is not stone cold. Keeping the cover secure day to day matters just as much, so look for an elastic or drawcord hem plus a few buckle straps that attach to the grill itself. No more coming outside to find the cover missing. Finally, consider a cover with handles, which makes taking it off far easier. A zippered grill cover is worth a look on built-in and island grills, where you may want access without removing the whole cover.
- Air vents
- Buckle straps
- Reinforced handles
- Drawcord hem
What a Grill Cover Should Cost
The price of a barbecue cover is subjective to your budget. We recommend finding the highest quality cover you can at a price that works for you, then watching for sales and seeing what companies offer when you sign up on their website. That often saves you money on shipping or unlocks discounts that stack with current promotions.
Judge value by cost per season rather than sticker price. A cover that fails in one summer is more expensive than one that lasts five years, whatever the shelf price says.
What Customers Say
Coverstore has been in the grill cover industry for over a decade, so you can trust the quality and design when you choose one of our covers.
"I needed a decent cover to protect a Lynx 36" Grill Cart. I couldn't stomach paying >$300 for the Lynx custom cover and this one fit the bill and my quality expectations very well. I sized this to fit with the side shelves in the down position, so it would not take up as much room when the grill is not in use."
"Extremely pleased with my cover! The measuring instructions were easy to follow so I was able to get a perfect fit for my odd-shaped grill. The blue is beautiful, complimenting my pool, and the quality excellent. I'm planning to order a second one in green for the Christmas season, since we can entertain in our yard year-round."
"The cover was made to specifications and fits great. The material looks like it will hold up well. Using the website to get the cover to specification was excellent. Overall I am quite pleased with cover and the process to get it. Website is far better than other competitors."
"Absolutely fantastic! My Weber Summit Grill Center did not provide a full cover. Coverstore was a perfect fit to protect against the elements!!"
Grill Cover Buying FAQs
What material is best for a grill cover?
Polyester at 600 denier or higher. It resists fading, will not crack or peel in extreme heat or cold, and lasts far longer than the thin vinyl sold in most big box stores. Commercial grade vinyl with a polyester lining is a reasonable lower cost option in mild climates. Canvas is sturdy and breathable but heavier to handle.
What does denier mean on a grill cover?
Denier measures the weight and thickness of the fabric threads. Higher denier means a heavier, more tear resistant fabric. 600 denier or above is the mark of a genuinely heavy duty grill cover. If a manufacturer does not publish the number, call and ask.
Do I really need a grill cover?
If the grill lives outdoors, yes. A cover keeps off rain, sun, dirt, and bird droppings, and it discourages insects and rodents from nesting inside. Against the cost of the grill itself, a cover is the cheapest protection available.
Should a grill cover be waterproof?
No, water resistant and breathable is better. A fully waterproof cover seals condensation in against the grill, which causes the mold, mildew, and rust the cover was meant to prevent. Water resistance combined with air vents gives protection without trapping moisture.
Are waterproof grill covers better than water resistant ones?
No, and this is the most common mistake in cover shopping. A waterproof grill cover has no breathability, so condensation forms underneath and sits against the metal. Water resistant grill covers shed rain and snow while letting that moisture escape, which is why every cover we make is water resistant with air vents rather than sealed.
What makes a grill cover heavy duty?
Fabric weight, seam construction, and hardware. Heavy duty grill covers use 600 denier or higher polyester, double stitched seams, and straps or a drawcord that hold in wind. A thin vinyl cover with a plain elastic hem is not heavy duty regardless of what the packaging says.
Is a custom grill cover worth it over a standard size?
It depends on your grill. Standard sizes ship immediately and fit common shapes well. Custom sizing is worth it for older or oversized grills, unusual shapes, and built-in islands, where a closer fit means less sagging fabric for wind and water to work against.
How do I measure my grill for a cover?
Measure width at the widest point including side shelves, depth front to back, and height from the ground to the top of the closed lid. Record in inches and measure twice. Full instructions are in our grill measuring guide.
Can you put a grill cover on a hot grill?
No. Wait until the grill is completely cool before covering it. A hot grate or firebox can melt, scorch, or shrink cover fabric, and covering a warm grill seals in heat and steam, which is how mildew and rust get started. Give a gas grill at least an hour after the burners go off, and a charcoal grill longer, since coals hold heat well after the flames die down.
What size grill cover do I need?
Take three measurements and shop by those rather than by a size label. Width at the widest point including side shelves, depth front to back, and height from the ground to the top of the closed lid. Choose the nearest size up, since a slightly larger cover with a drawcord works far better than one that will not close.
How do I choose the right size cover for my gas grill?
Measure with the side shelves in the position you plan to leave them, because folding them down can change the width by a foot or more. If your grill sits between two standard sizes, size up and cinch the drawcord, or order a custom size and skip the compromise.
Can I use a generic grill cover on a brand name grill?
Usually yes. Universal covers are sized by dimensions rather than by brand, and most cart and gas grills share a similar rectangular footprint, so a generic cover fits a Char-Broil, Nexgrill, or Dyna-Glo well as long as you measure first. Our guide to the best grill covers goes deeper on universal fit and when a brand fitted cover is worth it instead.
How long should a grill cover last?
A cheap vinyl cover often fails within a season or two. A heavy duty polyester cover should last years, and warranty length is the clearest signal of what a manufacturer expects from its own product.
Find Your Cover
Shop by grill brand, model, or your own measurements, in polyester and vinyl across every grill style.
With this guide you are on your way to a high quality cover that keeps your grill clean and protected year after year. For more on grill maintenance, read our guide on how to clean your grill, or see our roundup of the best grill covers if you would rather compare specific models.
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