Condo Blues: How to Make a Grill Cover

Sunday, May 19, 2019

How to Make a Grill Cover

The four seasons have taken their toll on the cover on my outdoor gas grill. I need a replacement grill cover. 

I don’t want to buy a vinyl grill cover because they rarely last more than two years in the elements. Fabric seems the best way to go since the BBQ cover I made from a drop cloth lasted seven years.
I planned to scope out the heavy duty outdoor fabric at the fabric store after a stop at Homegoods when I found a cheaper and cuter outdoor fabric option – an indoor /outdoor tablecloth.

Which also just so happens to go with this majestic beauty that I also picked up for the front yard.

Her name is Divine.

She is 6 feet tall.

And I love her.

Yes, I am THAT neighbor. You know the one.

How to Make an Outdoor Grill Cover from a Tablecloth

how to make a replacement gas BBQ grill cover
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I am using an outdoor table cloth for this project but you can use whatever sturdy outdoor fabric you like. You can even use a canvas drop cloth.

You will need:

One 60’ x 120’ oblong outdoor tablecloth (or two depending upon the size of your grill) – Make sure it is cloth. Do not use a vinyl tablecloth with a flannel backing or your grill cover will not last. You can find similar outdoor tablecloths like I used for this project here.



Straight pins


Sewing machine – I used this side cutter sewing machine foot  that turns your sewing machine into a serger and I can’t recommend it enough!

Disclosure: I am including affiliate links in this post for your convenience.
Make it:

1. Drape the tablecloth over the grill until the fabric is even on all four sides. Carefully away any extra fabric, we’ll need it in a later step.

how to make a bbq grill cover

2. Use the sewing gage to hem the raw edge ( s) by folding the raw edge over by 1/4 inch and then a second time by 1/4 inch and pin in into place with a straight pin.

how to hem a raw edge of fabric

3. Using the sewing machine and coordinating thread to sew the hem into place.

4. Drape the hemmed fabric over the grill right side (the pretty part) towards the grill. Use the extra fabric from Step 1 or a second table cloth to pin a rectangle of fabric to each end the of the grill cover.

how to make an outdoor grill cover
Tip: I found it easiest to pin the sides with the fabric on the grill cover. It allowed me to check and make sure the measurements of both side panels were the same size. Once I was happy with the size of the side panels, I trimmed the extra fabric from the sides before going inside of the house to sew it together.

5. Using the sewing machine and coordinating thread, sew each side to the grill cover. Remember to remove the pins as you sew! Sewing over pins is a great way to break a sewing machine needle or knock the machine out of alignment.

6. Turn the fabric grill cover right side out and protect that BBQ grill!

If you'd rather buy than DIY check out the following options - and more! - below!
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Teresa B said...

Great idea, I love that fabric (and I love Divine too). Thank you for sharing at The Really Crafty Link Party. Pinned.

Of Goats and Greens said...

This is pretty cool, and works with your stylish flamingo. Thanks for sharing with Fiesta Friday! said...

This is SO fun and cute! What a great idea...and so much more appealing to the eyes than the typical black or brown covers!

Heritage Home Ec said...

What a wonderful project! I love your flamingo.. so cute. Thank you for sharing. It's going to be fun to glam up our grill.

Marie-Interior Frugalista said...

Our BBQ is in desperate need of a new cover. I totally agree the expensive vinyl ones don't laat. I never would have thought to make one - with an outdoor table cloth. Very clever and thank you for the inspiration! Now I'm going to see if I can find one of those amazing serging feet for my sewing machine model.

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