Manufacturer recalls grill found faulty in CU tests

Onward Manufacturing of Canada Wednesday recalled three models of gas grills after the firebox of two samples of the Broil King Signet 90 melted in tests conducted by Consumer Reports.  The company's recall, which is expected to be followed shortly by an announcement from the U.S. Consumer Product Safety Commission, involves the Signet, Sovereign and Sovereign XL grills with model numbers starting with 986, 987 and 988. The serial numbers start with X, Y and Z.

In our routine test to determine how well a grill handles flare ups from fatty foods, a Broil King Signet 90's firebox melted, dripping molten metal onto the area beneath the grill, just missing the hand of one tester who was turning off the gas to the grill. (The space beneath the grill is where the propane tank is stored.) We subsequently tested two other samples of this grill: The firebox of one melted and that of the other grill had begun to crack and deform by the end of the test. Because we believe that the Broil King Signet 90 is dangerous and poses a serious safety risk, we have judged it Not Acceptable.

We reported our findings to the company that makes the grill, Onward Manufacturing, the CPSC and Health Canada, a government safety agency in that country.

Onward is offering owners of the affected grills a baffle. On its Web site it says: "A baffle has been designed which reduces flare-ups caused by grease and protects the cookbox from excessive heat should a grease fire occur." Owners can get the baffle by registering at the company's Web site  or by calling (866) 434-7455. A video posted with the recall notice shows owners how to install the baffle.

The model and serial numbers are located on the gas caution sticker, which is either on the bottom shelf near the wheels or on the rear cart support bar on the back of the grill.

We applaud Onward Manufacturing and the CPSC for the speed with which they responded.  Now that a retrofit kit is available, we hope to test it and report soon on how effective it is in addressing this serious safety problem.