Big Green Egg - EGGhead Forum - The Ultimate Cooking Experience...
Welcome to the EGGhead Forum - a great place to visit and packed with tips and EGGspert advice! You can also join the conversation and get more information and amazing kamado recipes by following Big Green Egg at:

Facebook  |  Twitter  |  Instagram  |  Pinterest  |  Youtube  |  Vimeo
Share your photos by tagging us and using the hashtag #EGGhead4Life.

In Atlanta? Come visit Big Green Egg headquarters, including our retail showroom, the History of the EGG Museum and Culinary Center!  3786 DeKalb Technology Parkway, Atlanta, GA 30340.

Rutland on my XL - start to finish

ChokeOnSmokeChokeOnSmoke Posts: 1,914
edited March 2012 in EggHead Forum
Installed a Rutland yesterday, that I got from Ron (RRP) back in February. I've been anxiously waiting for the weather to warm up here in Wisconsin.

I can't wait any longer, 45 degrees and sunny is going to have to do! I purchased a tube of Permatex Ultra Copper and a paint stripping wheel for the drill.

I first used a paint scrapper to remove the majority of the old (original) felt. It took maybe 5 minutes for both the lid and the base, it came off quite easily.

I then got the drill out with the paint stripper wheel to get the glue and remaining felt off. I spent 25 minutes each on the base and the lid. I had to recharge my drill between the base and the lid.

I now laid down the permatex in a zig zag pattern and used a trowel to even it out. I started out trying to do 5 inches at a time but that didn't work well for me. Too much going back and forth squeezing out permatex and pushing the Rutland it. I was making a mess and getting the permatex all over the gasket. I decided to go a 1/4 of the egg at a time. This went much smoother for me as I could just concentrate on laying the gasket down while bunching it. If I had to do it again, I think I'd put the entire permatex down first and then lay down the whole gasket. Maybe it was because it was only 45 degrees, but I never got the feeling that the permatex would have set/dried by the time I got all the way around? It really doesn't take long once the glue is on. I ended up using about 94 inches on my XL. It seems to cover the entire width of rim all the way around after "bunching" it. Also, I probably used about 1/2 the tube of permatex.

Loosening the top band:
<img src="; border="0" width="550"> <br><br><strong>Removed the lid:</strong> <br><img src="; border="0" width="620"> <br><br><strong>Removing old gasket with scrapper:</strong> <br><img src="; border="0" width="620"> <br><br><strong>Gasket off. Time to clean the edge:</strong> <br><img src="; border="0" width="620"> <br><br><strong>Paint & Rust remover for drill:</strong> <br><img src="; border="0" width="620"> <br><br><strong>Ready to start stripping:</strong> <br><img src="; border="0" width="620"> <br><br><strong>Lid is cleaned:</strong> <br><img src="; border="0" width="620"> <br><br><strong>Base is cleaned:</strong> <br><img src="; border="0" width="620"> <br><br><strong>Applying the Rutland with the Permatex:</strong> <br><img src="; border="0" width="620"> <br><br><strong>Rutland is on!:</strong> <br><img src="; border="0" width="620"> <br><img src="; border="0" width="620"> <br><br><strong>Seam in the back:</strong> <br><img src="; border="0" width="620"> <br><br><strong>Lid back on after 2 hours, time to cure:</strong> <br><img src="; border="0" width="620"> 
Packerland, Wisconsin


  • HicHic Posts: 350
    Very nice, looks good. I'm thinking I'll do the Rutland when the time comes.

    Large, medium, small and a mini. Egg'n, golfing, beer drinking, camping and following football and baseball.
    Atlanta NOTP suburbia.

  • Austin SmokerAustin Smoker Posts: 1,467
    Too funny...I put one on my large yesterday in much the same way -except I didn't even bother cleaning the top or removing it. Won't be able to cook on it til tomorrow nite, but really looking forward to a low&slow as i've been gasketless for over a year and the wind wreaks havoc with more!
  • Nice work and pictorial R. D.
  • ChokeOnSmokeChokeOnSmoke Posts: 1,914
    Austin Smoker wrote:
    i've been gasketless for over a year and the wind wreaks havoc with more!

    Same here. I had a huge 8-10 inch gap (gasket gone on top and bottom) but the rest of the gasket was fine, therefore the big air gap. I'd shut it down after a cook and all the charcoal would completely burn up anyway with the air getting in there.
    Packerland, Wisconsin

Sign In or Register to comment.
Click here for Forum Use Guidelines.