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)
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..
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.
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
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.
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.
You want to get 95% of the old off prior to proceeding. The next step is to clean it with some Acetone.
Acetone evaporates fast so be ready to start applying once you get it on your rag or paper towel.
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 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.
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.
Continue your way all the way around The Big Green Egg.
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.
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?
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!
Rutland Gasket Replacement (Big Green Egg or Kamado Joe)
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
- Use the scraper to remove the old gasket from the dome and base of the Big Green Egg or Kamado Joe.
- Rub with paper towel and acetone to get the remaining adhesive off for better contact.
- On the bottom ONLY, run an 1/8" bead of the Permatex around the base of the Big Green Egg (Centered).
- Cut 1 end of the new Rutland Gasket at a 45 degree angle.
- Start at the back of the Big Green Egg, center the gasket on the surface and lightly press it into the bead of Permatex.
- 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.
- 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.
- Once the gasket is pressed into the Permatex it is best to leave the lid open for an hour to let the Permatex setup.
- After an hour, close the lid and let the BGE sit for 12-24 hours prior to using it.
- After the 12-24 hours is up do a "cure" cook.
- 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.
Ben has a bachelor’s degree in construction engineering. When not constructing or remodeling X-Ray Rooms, Cardiovascular Labs, and Pharmacies, you can find him at home with wife and two daughters. Outside of family, He loves grilling and barbequing on his Big Green Egg and Blackstone Griddle, as well as working on projects around the house.
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PS
Friday 20th of October 2023
Thanks. I just noticed that Rutland actually makes a gasket made for the egg, using a 3/4 white fiber glass gasket, part number 99N17. Has that one ever been tried, it isn’t as thick and looks like it would require replacing both gaskets.
Ben Esman
Friday 3rd of November 2023
I have never personally tried that gasket for that very reason. I'd prefer to just place a gasket on the bottom and be done with it because the top can be a pain. If you give it a try, let me know how it turns out!
Gary
Friday 23rd of April 2021
In regard to prior comments, I think what cooks normal gasket material is high heat cooks, leaky gaskets (that allow heat to escape through the gasket) and flashbacks. My BGE is about 15 years old and I have replaced the gasket several times, the last with a high-heat nomex material. The last gasket has lasted for several years,but I am overdue for a gasket change. Having said that, I have also avoided high heat cooks due to the gasket fry effect. For the next change, I am going to try the Rutland. Realy wonder if I need to scrape the old gasket off of the upper lid. It is not disintegrating, just dry and hard. I think it would seal, just like the hard ceramic of the naked lid. What do ya think? BTW, impressed that the Smokin Joe comes with a Rutland type gasket. Have not seen the complaints that I see with the felt style.
Ben Esman
Monday 26th of April 2021
I would recommend removing the top gasket as well if you are going with the Rutland. The Rutland is thicker and I would be worried that the back of the BGE towards the hinge would bind and not allow the top dome to seal properly. The extra thickness may push the other gasket off in the back as well. Hope this helps? Yes, the Kamado Joe's definitely come with a different style gasket similar to the Rutland. I unfortunately only have a BGE so I can't speak to the performance of that one but it does seem to hold up well :) Good Luck!
Jim ludden
Saturday 6th of February 2021
I have a Big Joe 5-6 years old. I looking at using the Rutland gasket. Will the 95-6 that you used work on mine? I think the Extra large GE is similar to my Big Joe
Ben Esman
Tuesday 16th of February 2021
Yes, it should work, but it may require two packages due to the circumference being bigger. I also highly recommend tossing the adhesive that comes with it and pick up the Permatex adhesive.
Scott
Monday 23rd of November 2020
I disliked the Permatex. It heats up and definitely can taste in the hotter cooks like Pizza. As much has I hate replacing gaskets each year, I am back to it.
Ben Esman
Tuesday 24th of November 2020
Sorry to hear that, I've never had that issue! Was your bead too big or did you get it on the inner side of the rim? That is the only thing I can think of, but I've never had a problem with this and we do low and slow smokes and hot at fast for things like pizza and steak all the time. Either way, happy egging!
Reido
Tuesday 18th of August 2020
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
Ben Esman
Monday 14th of September 2020
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!