How to Convert a Propane Grill to Natural Gas With or Without a Conversion Kit

Published onApril 3, 2024
How-to Guides

Are you someone who worries about having enough propane in your tank whenever you want to throw something on the grill?

Or maybe you’ve already experienced running out mid-barbecue and now own three propane tanks as a result.

If natural gas is available to you, why keep putting yourself through the headache?

Converting your propane grill to natural gas will give you the peace of mind you’re looking for, right in time for grilling season.

Natural gas provides a continuous fuel source, is more cost-effective, and burns cleaner than propane. This means you’ll spend less money refilling tanks, and your grill components will last longer.

In this guide, we’ll explain how to convert a propane grill to natural gas in nine easy steps, including the materials you’ll need and the safety precautions to take. We’ll also walk you through how you can still make the conversion without a conversion kit.

Note: If you don’t already have a gas line running to your gas grill, you’ll need one installed from your natural gas meter. If you’re not familiar with gas lines or the components of a gas grill, we recommend having a licensed gas technician complete the conversion for you.

Table of Contents

A Step-by-Step Guide on How to Convert a Propane Grill to Natural Gas

The following guide will provide you with the necessary materials, safety precautions, and step-by-step instructions (with pictures) so your conversion goes smoothly.

Step 1: Determine if Your Propane Grill Can Be Converted to Natural Gas with a Conversion Kit

Before you begin the conversion process, you need to know if your propane grill can be converted to natural gas. Not all propane grills can be converted to natural gas.

Converting a propane grill to natural gas doesn’t mean just hooking it up to a natural gas line. You’ll need to make some adjustments.

For most grills, this means buying a conversion kit. Many manufacturers provide information about their conversion kits on their website or in the owner’s manual.

However, the availability of these conversion kits often depends on how old your grill is, as the manufacturer may have discontinued them.

If you can’t find any information about your specific grill online or lost your manual, you can check to see if there’s a sticker on your grill showing the model and serial number.

These stickers can be located in different places on your grill:

Next to your control knobs
Underneath or on the side of your control panel
On one of the grill legs
On the back side of one of the side panels underneath the grill head
On the inside of a door or on the side of a tank panel
On the grill column or post

Once you have these numbers, try calling the manufacturer to see if a conversion kit is available. If not, try calling around to local wholesale distributors. They will sometimes have older conversion kits for grills that are still stocked.

Even if there’s no conversion kit available for your grill, you can still convert it to natural gas by drilling out each propane orifice. We’ll go over how to do this later in this guide.

Step 2: Gather Your Materials

The materials included in a gas grill conversion kit will vary depending on the grill. Some will include a quick disconnect hose with the male and female fittings to connect the grill to the gas line, the orifices for the burners, and an orifice wrench to install them.

Others only include the natural gas orifices or will have a new valve assembly or regulator that needs to be replaced.

Here’s a complete list of materials you’ll need to make the conversion:

Natural gas hose and fittings
Natural gas orifices – Check with your manufacturer on size
Adjustable wrench
Channel Locks
Screwdriver
Socket wrench set (optional)
Teflon tape
Pipe dope

Step 3: Turn Off the Propane Tank and Disconnect the Regulator Line

To begin, turn the valve on top of your propane tank to the off position. Disconnect the connector hose from your grill and propane tank and remove the tank.

Step 4: Gain Access to the Propane Orifices

To access the propane orifices, remove the cooking grates and any heat shields that are located above the burner(s). Once these are removed, detach or loosen the burner or each burner tube and pull them away from the valve assembly.

Finally, disconnect the igniter module on the burner and remove it from inside the grill.

Some grills have unique burner designs or specific steps for removing these components, so always check your manual to see how to remove your burner.

Once the burner(s) are removed, you should have access to the orifices.

Step 5: Replace the Propane Orifices with Natural Gas Orifices

Using an orifice wrench or deep socket wrench set, remove the propane orifices from the valve assembly and replace them with the natural gas orifices that came in your conversion kit.

Before screwing them in, wrap the threads with Teflon tape to create a tight seal. One full rotation of Teflon tape should be enough.

When screwing in the new natural gas orifices, avoid over-tightening them, as this can damage the threads and cause gas leaks.

Once you’ve replaced your orifices, re-install all your components back into the grill.

Step 6: Prepare and Connect the Male and Female Fittings for the Natural Gas Hose

Take the male fitting for your quick disconnect hose and wrap the threads with Teflon tape as you did with your brass orifices. Starting at the bottom of the threads, wrap it tightly in a clockwise direction, overlapping each layer slightly. Continue until all the threads are covered.

Apply a thin layer of pipe dope to the threads of the fitting. Make sure to rotate the brush in the same direction as you wrapped the Teflon tape so the tape doesn’t start to unravel.

Using two adjustable wrenches, screw the male fitting into the valve assembly. Use one wrench to secure the valve assembly as you tighten the fitting with the other.

For the threads on your natural gas piping, apply a layer of pipe dope and tighten the female quick disconnect coupling onto the pipe. You may need a pair of channel locks to secure the gas piping as you screw the coupling on.

Step 7: Connect the Natural Gas Quick Disconnect Hose

Take the end of your new hose with the threaded collar and securely tighten it onto the fitting connected to your grill. Then, connect the other end of the hose to the quick disconnect coupling attached to your gas piping.

Step 8: Turn on the Gas and Check for Leaks

Once you have your quick disconnect hose connected, turn on the natural gas supply to the grill. Before lighting the burners, check for leaks by applying soapy water to all connections and watching for bubbles.

Wait a couple of minutes for smaller leaks to show. If you see any bubbles, turn off the gas and tighten the connection.

Step 9: Light Your Grill and Check the Flame

With the grill head open, light your burners and inspect the flame as you gradually turn the heat all the way up. You should see a steady blue flame as you raise the temperature.

If you start to notice a larger flame rolling out over your heat shields or any “roaring” noises, you may need to double-check the size of your orifices.

How to Convert a Propane Grill to Natural Gas Without a Conversion Kit

If you can’t find a conversion kit for your specific grill, you can still convert it by drilling the propane orifices that are screwed into each valve stem. These valve stems are controlled by the knobs on the outside of your grill, allowing you to turn the gas on and off and adjust the flame level.

When the valve is opened, gas passes through, and the orifices regulate the flow of gas. Each orifice has a specific maximum output for the type of gas being used, and the size of its hole determines how much gas flows into the burner tubes.

Propane orifices will have smaller holes than natural gas orifices because natural gas operates at a lower pressure than propane.

Using the correct orifice is critical when converting, as using the wrong one will lead to a dangerous situation where too much gas is going into the burners or the flow is restricted so much that the food doesn’t cook properly.

To drill out your propane orifices with the correct size for natural gas, you’ll need to know how many BTUs each burner produces. Once you know the BTUs, you can reference our propane to natural gas orifice conversion chart to determine the orifice size you need.

In the chart, locate the amount of BTUs required for each burner and match it with the corresponding drill bit size and gas pressure. The maximum incoming gas pressure for a natural gas grill is usually between 3.5 and 4 inches of water column (W.C.).

Once you know your drill bit size, you can use an orifice drill bit set to gently drill out each propane orifice to the correct size.

How to Drill Out an Orifice for Natural Gas

Accuracy and precision are extremely important when drilling an orifice for natural gas, so take your time during this process.

Before you start, apply a small amount of grease to the tip of the drill bit. The grease will capture most of the shavings to prevent them from getting clogged in the hole or stuck inside the orifice.

Position the drill bit against the orifice and, using your hand, apply steady pressure while slowly turning the bit to the right. To make this easier, you can use a pin vise to hold your drill bit and give you more leverage.

Continue until the bit has completely penetrated the orifice. Using your hand helps maintain a straight and even cut through the orifice hole.

Hand drilling a propane orifice for natural gas. Photo credit: Frank Hamilton – Propane and Gas Conversion Basics (How to)

It’s not recommended to use a hand-held power drill to drill out your orifice. Using a drill increases the likelihood of your bit slipping or drilling at the wrong angle. You also run the risk of making your orifice hole too big. If the orifice hole isn’t the exact size it should be for natural gas, it can lead to improper gas flow and potential safety hazards.

After drilling, use non-flammable compressed air or a soft brush to remove any remaining shavings from the orifice.

If you don’t have any experience drilling out orifices, it’s a good idea to have a licensed contractor handle this part of your conversion.

Safety Precautions to Take When Switching a Propane Grill to Natural Gas

When converting your grill from one fuel type to another, always prioritize safety. Working with gas can be dangerous, and it’s important to take the necessary precautions when converting your grill. Here are some guidelines to follow:

Always refer to the manufacturer’s guidelines and instructions when converting your grill.
Check for leaks before lighting the burners.
Some gas grills might require you to replace the entire gas valve, not just the orifices. Never attempt to convert a grill that’s not designed to be converted.
Make sure to use the correct size orifices for your burners.
You should always have a gas shut-off valve connected to your gas piping before the quick disconnect hose to turn off the natural gas supply when needed.

Frequently Asked Questions When Converting an LP Gas Grill to Natural Gas

Below are some questions and answers that can help you through the process of converting your propane grill to natural gas. This includes how to find a technician, the cost of converting, and how to figure out if you can use your current gas pipes.

Is it Easy to Find a Licensed Gas Technician for the Conversion?

Finding a licensed gas technician to convert your propane grill to natural gas shouldn’t be a problem in most areas. However, most of these contractors won’t want to be held liable for drilling out any of the orifices, so you’ll have more success finding one if you already have a conversion kit.

Start by contacting local HVAC or plumbing companies, or you can try your local gas company to see if they’ll do the conversion for you.

How Much Does it Cost to Convert a Propane Grill to Natural Gas?

The cost of converting a propane grill to natural gas depends on whether you hire a contractor or choose to do the conversion yourself.

If you hire a contractor, you can expect to pay anywhere from $150 to $350 for the conversion kit and the labor needed to make the conversion.

If you choose to convert your grill yourself, you’ll only need to purchase the conversion kit. However, you may need to buy some additional tools to complete the conversion.

What is the Cost of a Gas Grill Conversion Kit?

The cost of a gas grill conversion kit will vary significantly depending on the brand, the model of your grill, and the components included in the kit. Prices range from $50 to $100 on average, but high-end grills or specific brand-compatible kits can cost more.

These conversion kits typically include a natural gas hose and the necessary orifices to convert your propane grill to natural gas.

Why Can’t You Use Natural Gas on a Propane Grill?

You can’t use natural gas on a propane grill because the two gases operate at different pressures and require different orifice sizes.

Since propane operates at a higher pressure than natural gas, the orifices in your propane grill will be smaller than what’s needed for natural gas. If you were to use natural gas in a propane grill without adjusting the orifice size, it wouldn’t produce enough heat and lead to inefficient cooking.

To figure out what size orifice you need to use your grill on natural gas, you can check out our gas orifice conversion chart. Just match the orifice size with the BTUs used for each burner.

Can You Use the Same Pipe for Propane and Natural Gas for a Grill?

If you’re using a 20-pound refillable propane tank for your grill, you’ll need to have a new gas line installed to use it on natural gas.

However, if you already have a gas line running to your grill that branches off your house line from a larger 100 to 500 gallon propane tank, you may be able to use the same gas line.

To determine if you can use this same pipe on natural gas, you’ll need to calculate the pipe size. To do this, you’ll need to know the following information:

The maximum BTU load of your grill
What type of pipe it is
The inside diameter of the pipe
The total length of the gas line from your appliance to your gas meter.
The pressure being supplied to the grill from your gas meter
The pressure drop
The heating value of natural gas per cubic foot, which is 1,000 BTU/ft3

Write this information down because this is what you’ll need to find the right pipe sizing table to use.

Let’s go through an example to help you.

Skip these steps and use our gas pipe sizing calculator instead! It's easy to use, and it takes the guesswork out of making sure your gas line can handle the BTU load.

Gas Pipe Sizing Calculator

Let’s say you want to know if your existing propane pipe can be used for a natural gas grill that uses 65,000 BTUs. First, you need to know what type of pipe it is.

Determine What Type of Pipe You Have

The two most common pipe types used for propane or LP gas are copper tubing and gastite, which is a flexible stainless steel pipe. You could also potentially have Schedule 40 metallic pipe (steel) or CSST, a different type of flexible stainless steel.

Once you know what type of pipe it is, measure the inside diameter of the pipe to determine its size.

Measure the Total Length of Gas Line

Next, measure the total distance from your grill to your gas meter. When calculating the length of a natural gas pipe run, you should add additional length to account for the resistance caused by any 90-degree elbows used along the way. You can use the following equivelant lengths to account for these elbows based on the pipe size being used:

1/2″ Pipe: 1.55 feet/per elbow
3/4″ Pipe: 2.06 feet/per elbow
1″ Pipe: 2.62 feet/per elbow

Source: Table A.2.2 Equivelant Lengths of Pipe Fitting and Valves

For example, if you have a 1/2″ gas line with a 40-foot run and four elbows in line, you should add an additional 6.2 feet. This means your total length would be 46.2 feet.

Determine Your Gas Meter Pressure

If you’re already using natural gas in your home for other appliances, you can call your gas utility company to find out your gas meter pressure. This information should also be labeled on the gas meter itself.

Another easy way to tell what type of natural gas pressure you have is to look for any appliance regulators.

If regulators are installed before each gas appliance, you’re likely on a 2 PSI system. If you don’t see any regulators installed, you’re using a low-pressure system, which is considered ¼ psi or 7” W.C. (water column).

A caveat to this would be if you’re converting all your appliances from propane to natural gas.

In this case, you might not see any regulators on your existing pipe. That’s because propane operates at a higher pressure than natural gas, so regulators aren’t always necessary. But that doesn’t mean you don’t need them.

Once you switch over to natural gas, you’ll need to compensate for this loss in pressure. You can do this by increasing the size of your gas lines or asking your gas company to supply your home with a 2 PSI meter pressure.

When using this higher pressure, you’ll need to have regulators installed before each appliance. This is because the maximum inlet pressure for natural gas appliances is around 6 and 7 inches of w.c., so this 2 PSI needs to be reduced.

2 PSI gas meters should be able to handle the total BTU load of your appliances running simultaneously, but use our pipe size calculator to make sure your gas lines are large enough and that you install the regulators close enough to the appliances.

If you already have regulators installed that were used when you had propane, you can just adjust the outlet pressure on the regulator to match the natural gas pressure required.

Pressure Drop

For the pressure drop, it’s standard to use a 0.5” W.C. (Water Column) pressure drop, as this gives you the most margin for error when calculating pipe size.

After collecting all the required information, you can now select the right pipe sizing chart to use to determine if your pipe size is large enough to run on natural gas.

Here’s the information we’ve collected for this example:

The gas grill uses 65,000 BTUs (65 ft3)
The existing pipe is a ½” black iron or steel pipe
The total length from the meter to the gas grill is 46.2 feet.
The gas meter pressure is 7” W.C.
The pressure drop we’re using is 0.5” W.C.

Now, you would look for a schedule 40 metallic or steel pipe sizing chart for natural gas that shows an inlet pressure of less than 2 psi and a pressure drop of 0.5” W.C.

Using the specific chart below and rounding up our total length to 50 feet, we can see that our ½” steel gas line would be able to supply up to 72,000 BTUs/hr, which means our gas line is large enough to handle this gas grill.

If you have a low-pressure system and the chart shows your gas pipe isn’t large enough, that still doesn’t mean you have to replace it.

You can call your gas company and ask them to upgrade your meter to 2 psi, but keep in mind you would have to install appliance regulators for each of your natural gas appliances.

Final Thoughts

By following the steps given, you should be able to safely and successfully convert your propane grill to a natural gas grill with or without a conversion kit.

Just remember that converting a grill can be dangerous if not done properly, and it’s always best to consult with a professional to ensure the safety of yourself and your home.