Short answer: measure your grill and buy to the measurement, not to the model name. Width is taken at the widest point with the side shelves in the position you leave them, depth front-to-back including the lid handle, height from the ground to the top of the closed lid. Then add roughly 2–4 inches to width and depth so the cover drops over the grill instead of stretching across it.
The Pit Boss 1100 problem
A single model name can map to several genuinely different covers. The Pit Boss Pro Series 1100 is the clearest example we sell into:
| Cover | Stated size (W × D × H) | What it is built for |
|---|---|---|
| Pit Boss OEM Pro Series 1100 cover | 78" × 33" × 48" | Pro 1100 (PB1100PS1) with both shelves out |
| Common aftermarket "1100 Pro" cover | 62" × 24" × 47" | A tighter fit, shelves folded, also listed for 1000-series bodies |
| Triple-function combo cover | 69" × 24" × 51" | The pellet-and-gas combo body, which is taller and narrower |
All three are correct covers for something called an 1100. None of them is a substitute for measuring. The same pattern repeats across Weber Spirit and Genesis generations, Blackstone 28" and 36" griddles with and without a hood, Traeger Pro and Ironwood revisions, and Char-Broil model families that share a name for a decade.
How to measure, in order
- Decide the shelf position first. If you leave the side shelves up, measure with them up. Buying a cover for folded shelves and then leaving them out is the most common fit complaint there is.
- Width: tape measure across the widest point, handle tip to handle tip or shelf edge to shelf edge, whichever is wider.
- Depth: front to back at the widest point, including the lid handle and any rear hopper or shroud. Pellet grills usually lose here — the hopper adds several inches.
- Height: from the floor to the top of the closed lid at its highest point. If you want the cover to reach the wheels, measure to the floor; if you want it to clear a cart shelf, note that too.
- Add allowance: 2–4" on width and depth. Height is different — you generally want the cover to fall to within a few inches of the ground, not to pool on it, because a skirt that sits in water wicks.
Measurement checkpoints by grill type
| Grill type | Easy to miss | Fit priority |
|---|---|---|
| Gas cart grill | Side shelves and the tank on the side arm | Width with shelves out |
| Pellet grill / smoker | Rear hopper depth and chimney height | Depth, then height |
| Griddle (28" / 36") | Hood up vs no hood; the grease cup arm | Height, then width |
| Kamado / ceramic | Nest, side shelves and the top vent cap | Height to the vent cap |
| Built-in / island head | Countertop overhang and the drop-in lip | Head width, ignore the ground |
| Portable / tabletop | Folded leg profile | Closed-lid height |
What actually makes a cover last
- Vents. A sealed cover traps moisture underneath and encourages rust on the firebox and grates. Look for at least one pair of mesh side vents.
- Straps or a drawcord hem. Wind is what destroys covers. A cover that flogs against a corner will abrade at that corner within a season.
- Seam sealing over raw fabric weight. A heavier fabric with unsealed seams still leaks at the shoulder, which is where water collects.
- A slight peak at the lid. Water needs somewhere to run off. Flat-topped covers hold puddles.
- Let the grill cool completely before covering. Every cover manufacturer says this, and heat damage is not a warranty item.
When a cover is the wrong answer
A cover protects the outside of a grill. It does nothing for the parts that actually fail. If your grill is already showing rust-through on the firebox, warped heat plates, a burner tube with blocked ports, or a hopper that has taken on water, replace those parts first and then cover the result — otherwise you are wrapping a problem up and leaving it there until spring. The parts most worth checking before the season ends are the heat plates or flavorizer bars, the burner tubes and igniter, the grease tray and cup, and the cooking grates. All of them are cheaper than a new grill and all of them install with hand tools in under an hour.
One more thing worth doing at the same time: pull the grates out, brush the firebox, empty the grease tray and wipe the interior dry. Storing a grill with cooked-on grease under a sealed cover is what turns a two-season grill into a one-season grill, and no cover fabric can compensate for it.
Quick answers
Should the cover touch the ground? Ideally it stops just short. A cover resting in a puddle draws water upward and keeps the cart legs damp.
Universal or model-specific? Model-specific covers fit better around handles and hoppers. A universal cover in the right dimensions is fine if you accept some slack — slack plus wind equals wear.
Do I still need a cover under a patio roof? Yes, for dust, pollen, bird droppings and the humidity that causes surface rust on cast-iron grates.
Can I leave a cover on all winter? Yes, if it vents and if the grill is dry when you cover it. Check under it once a month.
My cover is 2 inches short on width. Will it stretch? No. Fabric under tension abrades at the corners and fails at the seam. Size up.
Shop covers
Browse grill covers and patio furniture covers, or start from your machine: Pit Boss, Weber, Blackstone, Traeger and Char-Broil. Covering everything before the cold sets in? See winterize your yard and grill replacement parts. Aftermarket and OEM-compatible parts; brand names indicate fitment only. Free US shipping.