Char-griller Duo with SFB

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For the rust, try a drill with a wire brush and some 120 grit sandpaper.  I bought three of these grills from Lowes for $125 total.  I got them at that price because they were really rusty; also, one was assembled and left outside in the elements and two were still in the box and left outside,  I'll post before and after pics in here and another thread.  

What I did was use the 120 grit sandpaper first to remove as much surface rust as possible.  Then I used the wire brush on the drill to remove the as much of the rust as possible.  Then I used 320 grit sandpaper to smooth it out.  Then I painted the outside with matte black rustoleum hi temp spray paint.
 
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