How to Make a Grill Cover for a Wood Pellet Grill

Item # X-HT-300227

Any dedicated Grill Master will tell you that it’s crucial to keep your grill clean and well-maintained—both inside and out. Well, we can’t help you clean your grill, but we can show you how to protect it year-round from harsh weather and other environmental factors with a heavy-duty, well-made grill cover. The ideal grill cover should be formfitting but also easy to remove, and store-bought covers are always inferior to one made to fit your grill’s exact measurements. Not to mention that making your own cover means you can use the best outdoor fabric and highest quality materials for a cover that will last for many years to come. Let’s get started!

Making a customized grill cover is easy with help from Sailrite.

The first step is to choose your outdoor fabric. You want a fabric that can handle the elements, will provide long-lasting durability with excellent tear and abrasion resistance, and that is highly breathable with mold and mildew resistant properties. We chose Odyssey® Marine Canvas Fabric for our grill cover as it meets all those criteria. Sunbrella Marine Grade, Top Gun and Sur Last outdoor fabrics are also great choices. Check out our Outdoor Fabric Selection Guide (300080XHT) for a full list of outdoor fabrics, their qualities and recommended uses.

A well-made grill cover consists of multiple fabric panels that will fit and conform to your grill’s shape perfectly. In this in-depth video tutorial, we’ll show you how to add seam allowances to your fabric panels so you get the perfect fit when you sew them together. We’ll show you how to measure your grill and calculate how much fabric you’ll need so you can purchase the correct amount of yardage. We’ll walk you through how to pattern your cover and all the sewing and assembly steps as well. And the finishing touch to your new grill cover is a useful drawstring sleeve threaded with a bungee cord so you can cinch the bottom to keep it in place during heavy wind, rain and snow.

Video Chapters:

  • Determining Fabric Required — 1:30 min.
  • Creating Patterning Frame — 2:08 min.
  • Patterning — 4:57 min.
  • Adding Seam Allowance & Cutting Patterns — 16:57 min.
  • Patterning Fabric — 20:40 min.
  • Creating Pleats — 24:43 min.
  • Joining Panels Together — 27:40 min.
  • Creating Sleeve for Drawstring — 45:45 min.
  • Installing Cover — 55:50 min.
  • Materials List — 56:43 min.

Materials List:

  • Filament Strapping Tape 3/4" (#5643)
  • Seamstick 3/8" Basting Tape for Canvas (#129)
  • Dura-Skrim® Patterning Material 74" (#122463)
  • Odyssey® Exterior Marine Fabric (#120416)
  • V-69 Linen Polyester UV Thread 4 oz (#106144)
  • Shock Bungee Cord 3/16" (#104328)
  • Barrel Lock Cord Closure 3/16" Double (#121615)
  • Sailrite® Woven Sew in Tag (#121604)

Tools List:

  • Gingher® Scissors Right Hand Lightweight 8” (#101017)
  • Tape Measure 120” (#102986)
  • Scribe-All Black Marking Pencil for Vinyl (#120682)
  • Sailrite® Canvas Patterning Ruler (#107040)
  • Multiuse Pins 1-1/2” (#102985)
  • Clear Acrylic Ruler 6” x 24” (#102400)
  • Sailrite® Ultrafeed® LS-1 PLUS (#300502)
  • Deluxe 5-1/2” Magnetic Sewing Guide (#103597)
  • Sailrite® Edge Hotknife Package (#103800)

If your wood pellet grill has a chimney, then you'll need to sew a separate tubular piece to cover it. That piece is then sewn to the main grill cover. Read our companion blog "How to Sew Round Ends: Wood Pellet Grill Chimney Cover" (#300228XHT) for more information.

Another great part about DIYing your own grill cover? You can make a whole matching set of covers for your entire outdoor living space! We’ve got blogs on how to make covers for your patio furniture, how to cover a chaise lounge chair, how to make a fire pit cover and more! Just go to the “Outdoor Living Projects” tab on our website and click on “Covers.”