Measure the grill with the lid closed at its widest, deepest, and tallest outer points — including fixed shelves and handles — then match those three numbers to the cover’s own finished dimensions.
Getting there takes three tape readings and one rule that almost every sizing chart buries: you measure the grill, but you buy the cover. Those are rarely the same numbers, and confusing them is why so many covers come back.
Below is the exact order to measure in, where fix-it mistakes get made, and how to read the seller’s spec sheet without getting fooled by a package dimension.
How Do You Measure a Grill for a Cover?
With the grill in its normal storage spot and the lid shut, measure width left to right, depth front to back, and height from the ground up. Include every fixed projection — side shelves, side burners, handles, knobs, rear vents, the lid handle — because the cover has to drape over all of it.
Lowe’s own measuring guide lays out the same three passes:
- Width — far-left to far-right outermost point, counting solid side shelves and side burners that don’t fold down.
- Depth — frontmost to rearmost, including protruding handles, control knobs, rear vents, and shelves.
- Height — ground to the highest point with the lid closed, usually the lid handle. Wheel height counts if it changes how far the cover drops.
Write the numbers in inches and round up to the next whole inch. Coverstore’s measuring guide recommends rounding up and building handles, knobs, wheels, and the closed hood into the reading. A grill that measures 47.5 inches wide is a 48-inch grill for cover purposes.
Why the Cover’s Listed Size Isn’t the Grill’s Size
Published cover dimensions describe the fabric shell, not the grill it fits. That single distinction explains most bad purchases, and it’s where the manufacturers genuinely disagree with each other.
- Some sizing guides tell you to add 2–4 inches to every dimension for easier on-and-off access.
- Formosa’s sizing chart says match the grill to a cover that’s equal to or slightly larger than the grill, and size up when you’re between sizes.
Three charts, three answers. The tiebreaker is simple: the cover maker’s own instructions beat any universal allowance. If the listing gives finished cover dimensions, compare your three grill numbers to those directly and skip the extra inches. Adding 3 inches to a cover already sized generously buys you a loose tarp that flaps in wind and puddles on the lid.
| Grill Type | What to Measure | Watch Out For |
|---|---|---|
| Freestanding cart grill | Full outer width, depth, and height | Fixed side shelves and side burners |
| Kettle grill | Complete assembled grill dimensions | Nominal bowl diameter ≠ cover width |
| Built-in grill | The insert opening | Not a freestanding cart footprint |
| Pellet grill | Outer dimensions including hopper | Hopper assembly changes the shape |
| Smoker | Outer dimensions including chimney | Vertical and offset stacks add height |
| Griddle | Full outer footprint | Side shelves and rear grease management |
| Electric grill | Outer dimensions with lid closed | Control housings and cord brackets |
Those numbers look strange next to a “22-inch” grill until you remember the cover wraps the whole kettle, not the grate. A cover built for a kettle won’t fit a cart grill with shelves, no matter what the inch label says.
If you’d rather skip the tape-and-spreadsheet routine, this roundup of tested BBQ covers by grill type lists actual measured dimensions alongside each pick.
Where Do Most Grill Cover Measurements Go Wrong?
The number-one error is measuring the cooking box or the grate instead of the outermost edges. That reading is always too small, so the cover arrives short on width or depth and never gets over the shelves.
Three more, in rough order of how often they bite:
- Trusting the package size. A box marked 50 inches may describe the carton, not the cover inside it. Coverstore’s guide is explicit that cover-style dimensions mean the cover itself.
- Measuring with the lid open. The lid handle is often the tallest point. Open-lid readings overshoot height and leave fabric pooling at the base.
- Skipping the model check on brand covers. A manufacturer’s cover built for one series rarely carries over to another, and listings show different dimensions across grill families even within the same brand.
Lowe’s measuring guide covers the width, depth, and height method in detail if you want a second walkthrough alongside the steps above: Lowe’s guide to measuring a grill for a cover.
What About Fit Allowances, Breathability, and Excess Fabric?
Aim for equal to slightly larger, and stop there. A cover that’s a touch oversized goes on easily and still sheds water. A cover that’s dramatically oversized drags on the ground, collects water in sagging folds, and cuts off the airflow that keeps condensation from forming under the fabric.
Built-in models follow a different rule entirely — measure the insert opening rather than a freestanding cart’s footprint, per Formosa’s sizing chart. Pellet grills, smokers, and griddles use the same three-measurement method as a cart grill, but the hopper, chimney, or control housing reshapes the profile, so verify model-specific compatibility before ordering. When a cover is genuinely between two sizes, size up, and let the cover maker’s own chart settle any remaining doubt.
The short version: measure the grill once, write the three numbers down, compare them to the cover’s finished dimensions, and confirm the maker’s instructions before you add a single inch of allowance.
Common Questions
Should I measure with the lid open or closed?
Closed. The cover drapes over the grill in its stored position, so a closed-lid reading reflects what the fabric actually has to clear. The lid handle is usually the highest point when shut, and measuring open inflates your height number, which leads to a cover that bunches at the bottom and traps moisture.
Do side shelves count toward the width?
Yes, if they are fixed. Fold-down shelves that drop flat can be excluded, but solid shelves and side burners that stay in place must be included in your widest left-to-right measurement. Leaving them out is the most common reason a cover won’t pull over the grill.
What if my grill falls between two cover sizes?
Size up rather than down, per Formosa’s sizing chart. A slightly generous cover still installs cleanly, while a tight one may not stretch over handles and knobs at all. Just avoid going so large that the fabric hits the ground or blocks ventilation.
Sources
- Lowe’s. “How to Measure a Grill for a Cover” Provides the width, depth, and height measuring method used throughout.
- Formosa Covers. “BBQ Cover Sizing Chart” Supports the equal-or-slightly-larger rule, between-size guidance, and built-in grill instructions.
- Coverstore. “How to Measure a Standard BBQ Grill” Supports rounding up, including projections, the 1–2 inch shorter breathability advice, and cover-versus-package dimensions.