Does the Perfect Flame grill recall go far enough?

Late last week the Consumer Product Safety Commission announced a voluntary recall of 24,000 Perfect Flame Double Lid Four Burner gas grills. The recalled grills, model number GAC3615, were made by Lucas Innovation Inc., of China and sold at Lowe’s Stores from October 2007 through July 2008 for about $300. The hazard is serious: The cooking chamber can "melt or ignite," posing risk of fires and burn injuries. According to the recall notice, there have been 175 reports of grill fires, and 25 reports of grills melting, some of which resulted in minor property damage. Owners are advised to stop using the grill immediately, disconnect the propane tank, and return the grill (without the tank) to any Lowe’s store for a full refund.

It wasn’t hard for us find complaints about Perfect Flame grills on Internet newsgroup forums and the complaints weren't limited to the GAC3615 model. In fact, our own database, which collects information from our readers, has two complaints about Perfect Flame grills catching fire; one specifically citing another model, an SLG2006.

A Fox television station in Tulsa has also reported numerous problems with Perfect Flame grills including an SLG2006 model. The video footage and consumer stories are striking. One Tulsa man reported that he found the lid and firebox of his Perfect Flame engulfed in flames after making a quick trip inside to finish preparing his meal. He also said that the grill exploded when he was trying to put out the fire with a fire extinguisher, spraying shards of hot metal across his deck and yard.

We contacted the reader who reported a problem with a Perfect Flame SLG2006 model to us, asking for some additional information about that incident. He told us that his grill suddenly ignited while he was cooking burgers. The metal in the firebox was actually burning and flames were spreading down the hose to the propane tank. His daughter burned her fingers trying to put out the fire. Fortunately, a neighbor, armed with a fire extinguisher, was able to douse the flames.

At our recommendation, he reported the incident to the CPSC as well as to the manufacturer, which was quick to make amends, arranging for him to choose a free replacement grill of any brand from a Lowe’s store.

How can a metal gas grill suddenly catch fire?  We spoke with a product specification engineer who used to write gas grill design specs, who believes that too much magnesium in the firebox's aluminum alloy could be the problem. Magnesium can burn and is very difficult to extinguish; such fires are best left for the fire department.

We called Lucas Innovation last Friday and spoke with a customer service representative who confirmed that the Perfect Flame grill recall was due to a problem with the material used for the cooking chamber. But when we asked for more specific information and whether the problem had shown up in other models, we were referred to the company's attorney who provided no additional information.

We contacted the CPSC’s Office of Compliance to find out why Perfect Flame SLG2006 wasn’t recalled along with the GAC3615. We noted the information we got from our reader, and expressed our concern that the recall did not include that model of Perfect Flame grill, which we know has had incidents and at least one injury. But according to the CPSC, current law forbids them from discussing an ongoing investigation. We were told they’d “look in to it.” We hope they do.

In our years of testing we've found it highly unusual for a grill to melt or catch fire. If  you’ve experienced problems with gas-grill fires, melting or deformation, please comment on this posting and be sure to report it to us as well as to the CPSC. The CPSC's recall system relies heavily on consumer complaints and without them many problem products wouldn't be recalled. Sharing this information can help us accomplish our mission of reducing the number of unsafe products in the marketplace and help protect consumers from serious injury.—Don Mays, Bob Williams

More on grills from Consumer Reports

• The Broil King Signet 90 986784LP recall and remedy
• Gas grill buying advice and Ratings
• Five most common grilling mistakes
• How to maintain your grill to prevent accidents

Comments

[Brian]

We purchased a perfect flame grill from lowes in boardman, ohio back in the summer of 2007. We spent nearly $400 with tax on the grill alone, let alone almost $50 with tax for the correct cover.
Lately the grill, model number slg2006c has been acting bizarre.
An example of this was tonight, when we were cooking chicken and steak on the grill, it became completely engulfed in big flames.
It was so intense the fire melted all 5 temperature controls and the metal sliding drawer underneath is completely heat warped.
Furthermore, my wife burnt her arms and fingers, fortunately not horribly bad, but painfully, attempting to turn the gas knob off to the propane tank, which was extremely hot as the flames drew near it. To make matters worse the tank being used was near full and in the garage behind us was another full refill tank for the grill and some gasoline for our power yard tools. This had the makings of a potential catastrophe, but was fortunately averted, by the quick thinking of my wife to grab the propane gas knob, and our neighbors sheltering our two young children. Another odd thing was that our grilling grates, which are heat resistant and made of porcelain, have partially cracked and burned up, as well as one of the main gas lines to the middle 4 burners, has a very small rupture present in it's length, thus making larger flames.
Upon analyzing these bizarre instances, we can come up with no logical explanation, as to how a stainless steel heat resistant, device can have so many unforeseen issues, all at the same time.
For the flames to melt parts and warp a majority of the metals,
it was obviously very hot so much so the grill is now unuseable.
We intend to report these instances of difficulties to the CPSC, so that they are made aware of the potential sudden hazzards the grill may present, as this is a truly dangerous item to cook on.

[Stan H.]

Good News! This is a follow up to my July 3rd post. As did acg, I contacted my local Lowe's in Cleveland, Tn and told them about my problem with the grill. I asked them if my model had been added to the recall and they told me just to bring it in and they would refund my purchase price no reciept needed. LeRoy in seasonal was extremely helpfull and gave me no run around whatsoever.

After much head scratching I did purchase a new grill but all the models have burner tubes that seem to be the same. This grill did have a 5 year warranty on the tubes so I guess we will see how it holds up.

Good luck to others. Once again, my thanks to the people I dealt with at the Lowe's in Cleveland Tennessee.

[acg]

I purchased a Perfect Flame GAC3615 last year. Within a few months the grill recall was issued, and I received a notice. However, my grill’s serial number was not one which was included in the recall. I kept an eye on the grill, but everything worked fine for almost a year. Then, last week I found my grill on fire. I again checked the serial number and check the recall notice. I saw this blog, but decided before contacting Lowes I would contact the manufacturer. I found their number here http://www.gac3615grillrecall.com/Qs%20and%20As_072408.htm . Although I was on hold for a very long time, the customer service person without hesitation told me to return the grill to Lowes for a full refund. I confirmed that this was so, even though my grill was not included in the recall. She stated that if there was any problem, I should have the local Lowes store call the same customer service number and that they would resolve the matter.

I’m going to hold off posting this until after I try to return the grill, so that I can make sure everything goes as they have stated.

My wife was doubtful, so I called Lowes before I took the grill up there. I spoke with the manager of the seasonal department, and he confirmed that they would issue me a refund for the grill. I took it back and even without a receipt, they refunded what we agreed was the purchase price I paid. I received a gift card credited with the purchase price plus tax. I am very satisfied with Lowes’ customer service on this matter.

[BB]

I have had the same problem as all the posters. Rusted, cracked burners giving way to a massive flame which, if not monitored, would have caught the grill on fire. Below is the email I sent to BBQTek and their response.

My email:
We purchased a Perfect Flame SLG2007A grill in the late spring / early summer of 2007 at Lowe's. It's entirely inoperable at the moment due to all the burners being rusted completely through.

After a few minutes of online research, I have become fully aware of the fire hazard posed by this grill due to the burners rusting prematurely. Clearly, this issue is widespread and while my grill didn't catch fire as many have, it was only because I recognized early that the burner was cracked. Lowe's no longer sells this brand of grills for this very reason I would surmise. While I'm aware that this particular grill model is not under a recall as is the 4 burner, double lid grill, my question is what is my recourse at this point? As I no longer have the purchase receipt, it appears that I am ineligible for the warranty which, frankly, I wouldn't be interested in anyway because of the continued fire hazard posed by this grill and its associated parts. Can I return to Lowe's? What are you advising all of your other customers who have purchased these grills?

Thanks in advance for your help.

Their response:
Dear Customer,


If you want to place an order can you please send me all the information together including your complete name, address, phone number, model number, serial number ( the serial number is located on the right side panel or back of your grill), and the part needed. Please reply this email with the previous one.

Thank you,

Hema Changea
Customer Service Representative
Toll free: 1.877.885.8227
Fax: 1.604.925.8203
hema@bbqtek.com
www.bbqtek.com

[Stan H.]

Newer units are no better than 06 or 07 models. I bought a three burner model SLG2008A last summer on the recommedation of the Lowe's employee. Lately I had noticed that I was having a great deal of orange flames in the rear of grill and was hearing a "popping" sound like little firecrackers! I thought that the burner tubes just needed cleaning but when I took out the grids to get to the burner tubes I discovered that they had rusted, swelled and cracked. Large spots had crumbled off probably while is was popping. I mentioned it to my dad and he told me about a recall he had seen about the perfect flame grills and directed me to this site. Guess the tubes are the same as older models. Grill is trash now. Will see what Lowe's says about an exchange or refund. As stated my grill is just barely one year old.

[Martin Davis]

I own a slg 2007a that caught on fire last month. I went inside my house to get a plate to put my steaks on, and when I came back out it was a towering inferno. Luckily it wasnt very close to the house and didnt explode.

[Jason]

Guess I'm the latest victim of the Perfect Flame. I received a SLG2007A as a gift in April 2008, which means a huge headache where reciepts are concerned. Grill worked great for me and I loved it for 1 year. The other day when I decided to give it a good cleaning I found 2 of the 3 burners cracked through about 1-2 inches from the rear connection. As with everyone else the screws were rusted solid and I had to use a dremel tool and a cut off wheel on the nuts. Why ANYONE would use a phillips head SCREW, the MOST likely fastener to strip, in a high heat enviornment like a grill is beyond me. There should have been a stainless steel hex-head bolt there instead. Now I'm counting myself extremely lucky that I didn't have the kind of fire so many of you are reporting. Stainless steel burners rusting through and cracking in 1 year? I think Lowes and Perfect Flame need to step up and make things right for all the other customers who bought this brand of grill. A recall due to an assembly mistake or design flaw might be limited to a certian model, but a recall due to MATERIAL DEFECTS is going to be spread to more models than one because of today's design and manufactuing processes which encourage using the same parts over several product lines. I guess I'll start with the calls to BBQTEK and Lowes tomorrow, but I don't expect much without the government stepping in. I was wondering why Lowes suddenly dropped the whole perfect flame line 6 months after I got my grill from them.

[Krystle]

This is SCARY!!!!! We have had our Perfect Flame slg 2007A for a little over a year now. Never had any problems till tonight. Walked inside after taking ribs off the grill to let the grill burn off came back out and the side of my house was completely burnt. My siding and part of my roof had caught on fire and all of my knobs were completly melted. WHY IS THERE NO RECALL ON THESE BBQS?! I think that we should all file a class action lawsuit against this company. I will contact Lowes tomorrow to see what they say.

[Shirley Mathers]

June 24, 2009

Perfectflame Grills,

To Whom It May Concern:

I am writing to inform you about a safety hazard which I recently encountered in the operation of our gas grill which was made by you.

Please note the following information:

Model SLG2007D
Ser # JY016298
Registration # EXS4229PF-77DYU-IP56
Purchased from Lowe’s 5-19-07

The morning after grilling two steaks the night before, as I prepared to cover the grill, I noticed the infra-red side burner, {Owner’s Manual, pg 6, item 14}on which the steaks had been cooked, was missing. It was lying upside down on the carpeted floor. After picking it up, I saw that it had burned a rectangle in the carpet which could easily have caused a fire.

Further examination revealed the burner had been held in place by only two small screws which had rusted through, thus allowing the burner to fall to the floor.

Most parts of the grill are stainless steel, but these two screws were ordinary steel, thus subject to rapid oxidation {rust} from the heat.

This problem was resolved by returning the burner to its proper position and fastening it there with two stainless steel bolts.

I STRONGLY RECOMMEND THAT THIS MATTER BE BROUGHT TO THE ATTENTION OF YOUR MANUFACTURING FACILITY.

After reading all of the other comments, I am now afraid to use this grill. We have had many over the years, but this one really scares me. All of the parts were stainless steel. Why would they use very small screws not made of stainless steel and only two to hold in a very hot infra-red burner, which gets really hot.

Robert Mathers

[tony poist]

We bought a perfect flame grill, two years ago and we will never buy another one because it is now junk. The burner melted and now i cant get the burner off to replace it. Do not buy one they SUCK!

[John Heathcote]

I have the SLG2007D Model and have also had the problem with the burners cracking and the grill catching fire. I clean the grill out twice a year. When I clean it, I remove the grates and the flame tents wire brush everything and then use a shop vac to remove all the debris. This still did not prevent me from having the grill fire. Luckily I caught it before it totally melted down. I need 4 new burners, 2 new grill grates, and 5 new flame tents. I have only had this grill for 2 years and I have always kept it covered when not in use. I thought this grill would last for at least 10 to 12 years since the burners were guaranteed for 10 years. I will never purchase another Perfect Flame grill again.

[Steve Hickman]

Also bought a Perfect Flame SLG2006C for father's day of 2006. I am an avid griller and take very good care of my grills. I was so excited to be getting a 5 burner - stainless steel exterior grill for my covered deck. For the money($400)it looked very high end compared to many others on the market. I do a complete cleaning twice a year and like mentioned above it is under a roof not out in the rain. A few weeks ago I noticed that when trying to light all 5 burners, after 3 all the flames nearly go out. So I was only able to use 3 burners. The next day I took the grates out and notices the burner tube holes have started to enlarge. The cover plates are so badly rusted and flaking they are dangerous to use. Plus like another person had commented on, the metal plate/bracket the burners mount to is so rusted away I cant even replace the burners if I wanted to. Just a quick search for parts looks like it would be $225 plus. Not including the bracket if it's even replacable. The SS burners are covered for 10 years, but it doesn't cover corrosion or damage caused by heat! Well isn't that great!! What a big disapointment this grill is. Something that costs this much and is taken care of should last longer than 3 years!

[Jennifer Small]

We bought the SLG2006B in September 2007. It blew up in October 2008, but it was the last use of the season by my husband, so I did not see until now when I went to clean it for the season how much damage there was and how dangerous it is. The story is the same as all the rest: blew up suddenly, contacted the company and have had no response...I filed a complaint with the Consumer Product Safety Commission and referenced this website. Wish I would have seen this before of course! Also hope others file a complaint- very simple form to do at www.cpsc.gov
Maybe something will be done to get this very dangerous product recalled if they continue to get complaints in large number!

[AMANDA M]

In response to my June 7th posting, my husband called Lowes the next day. The manager at first gave a hard time, asking how we could prove we bought it at their store (we have no receipt and paid cash for it). After hanging up the phone and discussing the issue my husband called back, the manager said "bring it in and we'll replace it". It was model SLG2007A. We took it to the store, the workers unloaded it and gave us a gift card for the price of the grill. We ended up paying $60 more and bought a Charbroil, which is still cheaper than if we just replaced the burners. Hope we have better luck with this one.

[Bogdan Nicolae]

I have similar problems with flare up caused by cracked burners my Perfect Flame SLG2006B grill. I just lodged a complaint with the CPSC. If enough of us complain about it, they will do something about it. Head over to their website now and make sure they are aware of your experiences with these grills.

https://www.cpsc.gov/cgibin/incident.aspx

[heather]

i have the slg2006c also last year i had to replace all 5 of my burners thank god i had the receipt because they have a ten year warrenty.the company sent me new ones at no charge. we keep the grill covered to. i am thinking about going the old fashion root charcol screw these gas jobs!

[Chuck Doty]

My wife and I bought a Perfect Flame SLG2007B for our 37th wedding anniversary as a gift to each other in June of 2007. A man in parking lot had just loaded one up on a trolley and said that the Perfect Flame was the best grill he had ever bought and was back buying another one to take to his cabin at the Lake of the Ozarks. WE, not knowing one from the other, bought the exact same model, he got. Our first experience with gas grills ended in disaster when, after only a year, our grill was ruined because it did not have a cover over the burners and grease dripped on the burner orifices and never really burned off. $400.00 thrown away on that one. However on this Perfect Flame,
after one week, the 2nd burner tube from the right [we have 4] developed a 3" long crack and we had to abandon that tube altogether. Well, we still had two side by side and one on the end as a warmer, if necessary. and since there was just the two of us---no great loss. For the first year it worked great. Little by little, the gas flames got bigger at the end of the 3rd tube from the right. The other end did not produce any flames for about 5 inches. When you pushed the control valve in to turn it to the next setting, flames shot out on the end of the pipe closest to you. It did not do that when we bought it. Now, the first burner tube we never used has cracked and a chunk about 4 " long has broken off of the pipe. Tonight, we shut the gas off and took the tank out. I should think that spending $400.00+ should get one with burners that work for at least 7 years instead of a week. And one would think that the most important part of the setup, the burner tubes, should be in stock at the supplier. My next gas grill will have parts available at the dealer or there will be no sale. WE are out $800.00+ in 3 years and with nothing to show for it except a good education in what not to do the next time. Does anyone make a gas grill in the USA that is built for quality rather than a cheap price?

[AMANDA M]

I FOUND THIS SITE LOOKING FOR REPLACEMENT BURNER PARTS FOR MY PERFECT FLAME GRILL BOUGHT AT LOWES. OUR GRILL ALSO WAS ENGULFED IN FLAMES WHILE COOKING BONELESS SKINLESS CHICKEN BREASTS (NOT A GREASY ENTREE). I HAD JUST FLIPPED THE CHICKEN AND LOWERED THE LID, THE TEMP READING ON THE HOOD WAS 325, I WALKED AWAY TO PLAY WITH MY CHILDREN AND MY DAUGHTER STARTED SCREAMING "MOM! MOM!" AND POINTING AT THE GRILL. I TURNED AROUND AND THERE WERE FLAMES SHOOTING OUT ALL SIDES OF THE HOOD, THE TEMPERATURE NEEDLE WAS BURIED AT 800 DEGREES. I SHUT OFF ALL BURNERS AND IMMEDIATELY TURNED OFF THE PROPANE TANK. I COULDNT LIFT THE HOOD, WHICH ALL THE PLASTIC WAS MELTING OFF. MY HUSBAND IS A FIREFIGHTER AND HAD TO USE HIS GLOVES FROM HIS TURNOUT GEAR TO OPEN THE HOOD TO DOUSE THE FIRE. AFTER IT COOLED DOWN AND WE GOT IT CLEANED UP WE NOTICED THE FIRE GOT SO HOT THAT IT CRACKED THE METAL GAS BURNERS AND UPON TOUCHING THEM CRUMBLED TO PIECES. FOR THE LAST WEEK MY HUSBAND HAS BEEN PICKING ON ME TELLING ALL HIS FRIENDS HOW I SET HIS GRILL ON FIRE, AFTER READING THIS SITE I AM CONVINCED IT WAS NOT MY FAULT. AND UPON LEARNING THAT EACH GAS BURNER TUBE IS 33 BUCKS IT IS CHEAPER TO BUY A NEW GRILL. THE HOOD OF THE GRILL IS ALSO BURNT UP AND CRACKED UP BOTH SIDES. MY HUSBAND WILL CALL LOWES TOMORROW, BUT READING THIS, DOESN'T SOUND LIKE IT WILL DO ANY GOOD.

[Brian M.]

Thanks Consumer Reports for posting this Blog.
I also have the GAC3615, but with a date code that is NOT part of the recall.
So I did not think I had a problem until:
1. I saw a crack in one of the burner tubes.
2. I saw all these consumer comments.

I bought this "death trap" over a year ago.
My plan is to now go back to Lowes and try to replace it for something a little more friendly to life and limb.
What do you suggest I do if (or when) Lowes pushes back and tries to send me to the manufacturer behind the curtain?
Thanks

[George Corron]

I have a SLG2007A and noticed the rear of the flames were looking really wierd last time I used it. I took it apart this evening and found the tubes completely cracked into pieces!!!!

Considering the price of the tubes, I'm pretty certain I would have replaced the entire thing with anything other than Perfect Flame!!

Glad I found this site, I'm going to remove the bottle in case it spontaneously combusts!!!

Thanks guys

[James]

WOW! I have a SLG2006C purchased from Lowes and like other users I thought it was user error but after reading all these posting, I change my mind. I purchased mine about 3 years ago. Within the first year, I had a similar situation where the whole inside caught fire. It scorched the outside of the stainless steel lid and shortly afterwards I had to replace the burners. I have never left it unattended again.

[Jim Lawrence]

We have had our Perfect Flame Model #GSC3318 (which we bought from Lowes) for about 2 years. While using it this past weekend one of the burner tubes failed and if I had not caught it when it did - I am sure there would have been damage to the deck and house!! The teperature was well over 1000 degrees with flames shooting out the lide. It looks like these are the same tubes used on the 3615.

[Todd Gates]

Wow do I feel stupid. Can't believe I fell for this barbeque grill like all the other's here did too. This grill is the biggest waste of money I've ever spent my time with. I've only had the grill for two years and in two years I'm out the nearly four hundered dollars I spent on it cause I'll be buying a new one this year. All the burners are out and completely rusted along with the racks and splash guards. There's rust on the outside on the lower doors and even on the top lid even though it's been covered since day one with a grill cover. Another quality product made in CHINA! ! !

[matt davis]

WoW! I had no Idea that my grill was a ticking timebomb! Last Thursday{21st} i turned on the grill and before i could get back with the meet it was in flames. I have never seen white, bright flames like that, as if someone was welding. My son grabbed a hose but thank God I stopped him. I grabbed a shovel and used dirt from the flowerbed to put it out. Whin the shovel touch the grill it would arch and spark like nothing I have ever seen before. I managed to shut the gas off and remove the tank while burning my hands and scorching my hair. The tank was very hot but i couldn't let the thing blow up. who knows what would have happened or who could have got seriously hurt.
I called Lowes and they wanted to know how long that I had it. When I asked if that mattered she said that they had a problem with this grill months ago and they recalled them and that I should have brought it in then. I came unglued! If they know that there are families out there that have this grill they should warn them. I told her that i bought it with my Lowes card and they could have easily researched that. She told me that she would give me a refund but I had to bring it down there. this grill is a burned up mess and I told her to have someone come and pick it up, but she refused and let me know that without the grill I would get nothing.
So I guess I'll be spending Memorial Day cleaning the dirt off and transporting this Death Trap to the store.
I wonder if there isn't grounds for some type off class-action lawsuit. It's like they don't care if there is someone out there getting ready to bar b que not knowing that he could be lighting up his Fate!
I have plenty of pictures if anyone would like to see the mess.

[Bob Groh]

My comments are the same as others pretty much. Model SLG2006 purchased at Lowe's December 2006 as a present for my son-in-law. Fired up (how apt!) about 3 weeks ago and fire out the back! I just got back from checking it out - burner tube rusted out and cracked about 1" from back and that is where fire popped out. Other burners just waiting to break - 3 others broke when I twisted them. Pieces literally came off in hunks. What a piece of junk and bloody dangerous too!! A real hazard - Lowe's should be ashamed of themselves. We are looking for the receipt and I will pay them a visit tomorrow to see what can be done. Meanwhile I'll continue to peruse the web.