First we need to determine if The Big Green Eggs gasket needs to be replaced. Once it is determined that The Big Green Egg needs a new gasket we can follow the steps below to successfully install a new Rutland gasket on The Big Green Egg.

Does your Big Green Egg Gasket Need to be Replaced? (3 Ways to Tell)

Big Green Egg Smoking

One easy way to tell if your gasket needs to be replaced is simply firing up The Big Green Egg for a cook. When The Big Green Egg is heating up all the smoke should be coming out of the daisy wheel / top vent.

Notice in this photo that the smoke is seeping through the bottom and the top done. This is a sure sign that the gasket has failed and should be replaced..

Big Green Egg Lower Vent Setting to Achieve 225 Degrees

Another way to tell if The Big Green Egg needs a new gasket is to try and dial the temperature into 225 degrees. If you have the daisy wheel on and the draft vent cracked as shown above and have issues getting The Big Green Egg that low then there is a high probably air is seeping in and the gasket needs to be replaced.

Big Green Egg Bad Gasket

A third way to check the gasket is to physically look at it. The gasket should not look like the photo above. In this case, it is pretty easy to see why I am replacing this particular gasket.

A Couple other BGE Gasket Tips and Tricks prior to replacing the Gasket

Your Big Green Egg will continue to operate just fine without the gasket (outside of needing to close the lid a little softer than normal). With that being said you may run into troubles getting the lower temps dialed in. Another good reason to replace the gasket is it acts as a closing cushion as well. I’ve been having to close mine very softly as it is basically ceramic on ceramic.

Another quick reason to spend the money on a new Rutland gasket for the BGE is to save money. If your existing gasket is not working properly it will allow air into the egg when you close it down.

This keeps the BGE hotter longer and slows down the cooling process. Which means you are burning more lump coal than you need to in which this is also slowly costing you more money.

For me, I purchased my Big Green Egg used and it is probably 5+ years old. So judging by the existing gasket, it needed to be replaced at least 4-5 years ago. The good news is, that replacing the gasket on The Big Green Egg is easy even with a Rutland gasket!

Items required to replace Big Green Egg Gasket

  • Acetone
  • Permatex Ultra Copper
  • Rutland Gasket The Large Egg Part Number is 95-6, 7 Foot 5/8″ Gasket Kit, which will work on a MD, SM or any Mini Max as well. Anything bigger than the large will require two of these gaskets.
  • Scraper
  • Rubber Gloves (optional)
  • Large piece of cardboard (or similar throw away item)

How to Install the Rutland Gasket on The Big Green Egg?

Preparing The Big Green Egg for The Rutland Gasket

Removing the Big Green Egg Gasket

While starting out removing The Big Green Egg’s gasket with a drywall blade is faster I prefer to start with a shim, which is made of wood. This is a lot less abrasive so it is easier on the ceramic. Simply start scraping the old BGE gasket off.

Scraping The Big Green Eggs Old Gasket Off

There will be tougher areas that the shim wont quite work for. Utilize the drywall blade as a scraper to get these areas cleaned off.

Acetone Prepping for Rutland Big Green Egg Gasket

You want to get 95% of the old off prior to proceeding. The next step is to clean it with some Acetone.

Applying Acetone for Rutland Big Green Egg Gasket

Acetone evaporates fast so be ready to start applying once you get it on your rag or paper towel.

Cleaning with Acetone for Rutland Big Green Egg Gasket

Clean the entire BGE gasket surface area. You wont get it all but if you are a perfectionist you can buy a 3M stripe off wheel. These are the same that are used on car paint to remove a decal so they are pretty harmless to the BGE.

With that being said, I’ve never had a problem with leaving 5% or less. This is given it is super caked on. It isn’t worth scratching or digging into your Big Green Eggs’s delicate ceramic.

Repeat this process for the dome of the Big Green Egg.

Install the Rutland Gasket on The Big Green Egg

Do yourself a favor and just toss the Rutland adhesive. The Big Green Egg gets to hotter temps than what the Rutland gasket cement is designed for. Your better option is to install the Rutland gasket on the Big Green Egg with Permatex’s Ultra Copper. This can better withstand the higher heat.

Another nice thing to be noted is that you only need to replace one of the two BGE gaskets when using the Rutland gasket. Proceed with cleaning the dome of the Big Green Egg, but once the cleaning is complete the top is done!

One final note prior to starting the installation should you need to continue and do so. This gasket is made of fiberglass and can be itchy. With that being said you may want to wear a pair of rubber gloves. I’m used to working with fiberglass in past jobs so I’m pretty much immune to the itchiness.

Apply 1/8" Bead of Permatex Ultra Copper to The Big Green Egg for Rutland Gasket

Apply a 1/8″ bead of Permatex Ultra Copper around the ring of The Big Green Egg. Make sure the bead stays in the middle so that when you compress the gasket it doesn’t squish outside the Rutland Gasket.

Applying Rutland Big Green Egg Gasket

If you are right handed start on the back left hinge corner (reverse if you are left handed). Start out by cutting the end at a 45 degree angle. Proceed with slowly working your way around the rim of the BGE. Just keep centering and pressing the Rutland Gasket into the Ultra Copper without stretching the gasket.

Applying Rutland Big Green Egg Gasket

Continue your way all the way around The Big Green Egg.

Applying Rutland Big Green Egg Gasket

Cut the Rutland gasket at the same 45 degree angle closing the gap. The gasket will fur out on the ends a little, this is fine as long as you don’t cut it short. Simply try to push the frays down into the Permatex Ultra Copper. After a couple uses this will stay, lay flat and not stand out as much and still create a great seal.

Applying Rutland Big Green Egg Gasket

Get a piece of cardboard and lightly press the gasket all the way around The Big Green Egg. Remove the cardboard and let the Big Green Egg sit with the lid open for a hour.

How to Cure the Big Green Egg Rutland Gasket?

Final Cleaning Rutland Big Green Egg Gasket

After a hour has passed it is recommend to close the lid and let it sit for 24 hours. Always try to do this installation when the weathers forecast is looking good. Or if you find yourself in trouble with weather get a tarp over the Big Green Egg, move it to the garage or an overhang.

After about 24 hours has passed it is now a good idea dial your egg into about 250 degrees for an hour or two to allow the curing to fully complete.

After the curing has fully completed I always recommend a good clean burn. I do a clean burn to get rid of any debris that may have fallen in the firebox. Plus it is good to do every so often depending on your cooking frequency. While doing this I also recommend inserting your Big Green Egg plate setter, grate and even pizza stone if they haven’t been cleaned in a while.

This will conclude the installation of your new Rutland gasket on The Big Green Egg! Enjoy all your future cooks and don’t forget to comment or reach out if you have any questions or run into any trouble!

How to Replace The Big Green Egg Gasket w/ Rutland Gasket
Yield: New Gasket Seal on Big Green Egg or Kamado Joe

Rutland Gasket Replacement (Big Green Egg or Kamado Joe)

Prep Time: 10 minutes
Active Time: 20 minutes
Additional Time: 1 hour
Total Time: 1 hour 30 minutes
Difficulty: Easy
Estimated Cost: $20

Have a leaky seal, disinigrated seal, trouble hitting the low temps or simply looking to replace the seal on your Big Green Egg or Kamado Joe then look no further! This Rutland Gasket Replacement will solve all your problem for many years of successful cooks to come.

Materials

  • Paper Towel
  • Acetone (Optional)
  • Permatex Ultra Copper
  • Rutland Gasket - Part Number 95-6, 7' 5/8" Gasket Kit

Tools

  • Scraper
  • Rubber Gloves (Optional)
  • Large Piece of Cardboard

Instructions

  1. Use the scraper to remove the old gasket from the dome and base of the Big Green Egg or Kamado Joe.
  2. Rub with paper towel and acetone to get the remaining adhesive off for better contact.
  3. On the bottom ONLY, run an 1/8" bead of the Permatex around the base of the Big Green Egg (Centered).
  4. Cut 1 end of the new Rutland Gasket at a 45 degree angle.
  5. Start at the back of the Big Green Egg, center the gasket on the surface and lightly press it into the bead of Permatex.
  6. Continue all the way around the base of the BGE and at the end overlap and cut another 45 degree angle to finish the gasket.
  7. Take a big piece of cardboard and place it over the rim of the base on the BGE and press down all the way around the BGE to push the rest of the gasket into the Permatex so it grabs good.
  8. Once the gasket is pressed into the Permatex it is best to leave the lid open for an hour to let the Permatex setup.
  9. After an hour, close the lid and let the BGE sit for 12-24 hours prior to using it.
  10. After the 12-24 hours is up do a "cure" cook.
  11. Fire up the BGE and let it cook at 250 degrees for an hour or two which will help ensure the Permatex is fully cured prior to any cooking.

Notes

Acetone is noted as optional as some say that the ceramic can absorb it. If it is just dabbed on the rim to remove any other debris I've found that it is so little that it is a non issue.

Author

I have a bachelor's degree in construction engineering. When I’m not constructing or remodeling X-Ray Rooms, Cardiovascular Labs, and Pharmacies...I’m at home with my wife, two daughters and a dog. Outside of family, I love grilling and barbequing on my Big Green Egg and working on projects around the house.

8 Comments

  1. Bill costello Reply

    Why only put the gasket on the bottom. Do you still get the same seal? I assume you still take off the old gasket and scrape down lid but not having to remove it makes the job much simpler

    • Good afternoon Bill,

      The Rutland gasket is actually thicker which allows the dome to go without one, and no you won’t have any issues with it sealing. Also note that the gasket usually comes with adhesive but I highly recommend just tossing that one and picking up the Permatex Ultra Copper. The Permatex Ultra Copper handles the higher temps better if you are looking to sear steaks or fire up some pizza’s. Let me know if you have any other questions, good luck and happy Memorial Day!

  2. Hey Ben,
    This looks great!
    Any concerns with potential shedding of fiberglass from the gasket into food being grilled/smoked?
    Thanks and best regards.
    Russell

    • Good morning,
      I believe Rutland has to put that it isn’t food safe for liability reasons but I’ve personally never had an issue with this. It also isn’t like the food is ever touching the gasket either. Between that and even if a fiber did become free, heat rises and I would think it would just kick it out the top of the BGE / daisy wheel. I’m not saying it isn’t possible, but I’ve personally never had an issue with this concern. Happy Eggin’!

  3. Thank you for the eggcelent post! I did notice that the Instructions are missing a step between #7 and #8. In the detailed area you mentioned that after pressing on the cardboard, leave the egg open for an hour before closing. I would assume that this is so the lid doesn’t incidentally pickup some of the sealant and stick closed.
    Thank you again for the post! Cheers

    • Thank you for pointing this out! This has been updated, hopefully your gasket swap was successful and you are back to smoking some awesome food!

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