How to Measure Your Grill for the Perfect Grill Cover

The short answer: Measure the grill’s width (including side shelves), depth (including handles), and height (including the lid and any chimney), then add at least 2 inches to each dimension for a comfortable fit. Always measure at the widest points, and for non-rectangular grills, take additional measurements of the cooking surface area and overall shape to ensure the cover matches.

Why Accurate Measurements Matter

A grill cover that’s too small will stretch, tear, or leave parts exposed to the elements. One that’s too large can billow in the wind, gather water, and become a breeding ground for rust. The right cover protects your investment, keeps your grill clean, and extends its lifespan. By taking a few minutes to measure correctly, you’ll avoid the frustration of buying a cover that doesn’t fit.

Before you start, make sure the grill is cool and clean. Remove any accessories like rotisserie rods or side burners that might stick out. You’ll need a flexible tape measure (the cloth or vinyl kind works best for curves), a notepad, and a pen. Write down every measurement as you go.

Step-by-Step Measuring Guide for Different Grill Types

1. Gas Grills (Standard 3-Burner and Larger)

Gas grills are the most common, and they usually have a rectangular footprint. To measure correctly:

• Width: Measure from the left edge to the right edge of the grill, including any side shelves if they are permanently attached. If the shelves fold down, measure from the outer edges of the folded-up position for a snug fit, or from the extended position if you prefer a cover that fits over the open shelves.
• Depth: Measure from the front edge (including the handle) to the back edge. Don’t forget to include the thermometer if it protrudes.
• Height: Measure from the ground to the highest point of the closed lid, including the chimney or vent cap. If your grill is on a cart, measure the total height from the floor to the top.

Add 2-3 inches to each dimension to allow for the cover to slide on easily and accommodate any protruding parts. For example, if your grill is 48 inches wide, 26 inches deep, and 44 inches tall, you’d look for a cover roughly 50-51 inches wide, 28-29 inches deep, and 46-47 inches tall.

2. Charcoal Grills (Kettle, Kamado, and Barrel)

Charcoal grills come in various shapes, so measuring is a bit different:

• Kettle-style (round): Measure the diameter of the grill at its widest point (usually the top edge of the bowl). Then measure the height from the ground to the top of the dome. A round cover should be slightly larger in diameter, typically 2-4 inches more.
• Kamado-style (egg-shaped): Measure the circumference of the grill at its widest part (around the middle). Use a flexible tape and wrap it around. Then measure the height. For kamado grills, you might need a cover specifically designed for that shape, so check the product specs for the diameter and height.
• Barrel-style (offset smokers): Measure the length of the barrel (front to back), the depth (side to side), and the height from the ground to the top of the chimney. Include the firebox and any side tables in your width measurement.

3. Pellet Grills and Smokers

Pellet grills often have a distinctive shape with a hopper on one side and a chimney on the other. Measure:

• Width: From the far left (including the hopper lid) to the far right (including any handles).
• Depth: From the front of the grill (including the handle) to the back of the hopper.
• Height: From the ground to the top of the chimney or the highest point of the lid, whichever is taller.

Pellet grill covers often have cutouts for the chimney, so look for covers that match your specific model or have a drawstring to accommodate irregular heights.

Bonus Tips for Odd Shapes and Accessories

If your grill has a side burner, a rotisserie motor, or a front shelf that folds down, decide whether you want the cover to fit over them or not. Many covers are designed to fit over folded shelves, so measure accordingly. For odd-shaped grills, trace the outline on a large piece of cardboard and measure that shape. You can also use a string to measure curved surfaces and then lay the string flat against a ruler.

Another tip: when in doubt between two sizes, choose the larger one. A slightly too-big cover is better than one that’s too small, as long as it has a drawstring or elastic hem to keep it snug in wind.

Common Measuring Mistakes to Avoid

• Forgetting to measure the highest point: The chimney or thermometer often sticks up, and if you don’t include it, the cover won’t fit over the top.
• Measuring with the lid open: Always measure with the grill closed, as that’s how the cover will be used.
• Not accounting for handles: Handles can add several inches to the depth and width, so include them in your measurements.
• Ignoring the cart or stand: If your grill has a cart with wheels, measure the entire unit, not just the cooking chamber.
• Relying on the model number alone: Grill models can vary in size even within the same brand. Always measure your specific grill.

How to Use Your Measurements to Choose the Right Cover

Once you have your measurements, you can shop for a cover with confidence. Most cover manufacturers list the dimensions they fit, so compare your numbers to the product specifications. Look for covers that are at least 2 inches larger in width and depth, and at least 2 inches taller than your grill. Also, consider the material: waterproof materials like polyester with PVC backing are durable, but breathable fabrics are better for high-humidity areas to prevent condensation.

If you’re unsure where to start, our best grill covers guide reviews top-rated options with exact dimensions and features, helping you match your measurements to a quality cover.

Frequently Asked Questions

Q: Do I need to measure the side shelves even if they fold down?

A: Yes, measure them in the position you’ll most likely use them. If you always fold them down, measure with them folded. But if you sometimes leave them up, measure with them up and look for a cover that can accommodate that. Many covers are designed to fit over folded shelves, so if you measure with them up, you’ll get a larger cover that also works when folded.

Q: What if my grill has a chimney that sticks out sideways?

A: Measure the chimney’s height and width separately, and add those to your total height and depth. Look for a cover with an adjustable drawstring or a vented design that can accommodate the chimney’s position.

Q: Is it better to get a cover that’s too big or too small?

A: Too big is generally better, as long as it has a way to tighten around the base (like a drawstring or elastic). A too-big cover won’t strain seams and will still protect the grill, but a too-small cover will stretch and may tear. Just ensure it’s not so large that it traps moisture against the grill, which can cause rust.

Taking accurate measurements is the first step to protecting your grill from the elements. With these steps, you’ll find a cover that fits like a glove and keeps your grill in top shape for years. For a curated list of durable covers that fit various sizes, check out our recommended picks.

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