A grill cover fits when its width, depth, and height meet or slightly exceed your grill’s outer measurements with the lid closed, including every fixed shelf, burner, handle, and knob.
For the full breakdown, see our best BBQ Grill Covers guide.
Buy by the nominal “60-inch” label alone and you will likely end up with a tarp that pools on the patio or a sleeve you wrestle off every morning. Covers are sold on outer dimensions, which change the moment a side burner or lid handle enters the picture. Three measurements and one decision about fold-down shelves are all it takes.
What Exactly Do You Measure On A Grill?
Measure the outermost width, depth, and height with the lid closed, catching every protrusion. Skip the firebox-only shortcut — it is the most common reason covers arrive too small.
- Width: Far-left edge to far-right edge. Non-folding side shelves or side burners are part of the number.
- Depth: Front to back. Control knobs, lid handle, and rear vents that bulge past the body count.
- Height: Ground to the highest point, almost always the top of the closed lid.
Work with the lid shut — an open lid can add several inches, producing a cover that hangs loose and flaps. Wheels and casters are part of the base, so start at the floor, not the bottom of the legs. Kettle grills break the pattern: measure the diameter across the widest part of the bowl. Built-in grills: measure the insert if recessed, the whole outer frame if standalone.
The Fixed Or Fold-Down Shelf Decision
Side shelves count in width only if they stay up — and you must decide now whether they will be up or down while the grill sits outside. This is a storage decision, not a measuring one. Measuring shelves up but storing them down leaves a cover that sags and collects water; measuring them down but storing them up leaves a cover that will not close. Either choice is fine; mixing the two is not. Recessed side burners, towel bars, and warming-rack hinges rarely look like they add width. They do.
How Much Clearance Should A Grill Cover Have?
Both point the same direction: a little slack, never a second skin. A cover that seals tight traps moisture against metal, which is how a grill rusts under a “protective” cover. Too tall and the hem drags on the ground and wicks up water; too short and the bottom few inches sit exposed. Land in the middle.
| Dimension | How To Measure | What People Forget |
|---|---|---|
| Width | Far left edge to far right edge | Fixed side shelves and side burners |
| Depth | Front face to rear face | Knobs, lid handle, rear vents |
| Height | Ground to highest point, lid closed | Wheels at the base, open-lid readings |
| Kettle grills | Diameter at the widest point of the bowl | Treating it like a rectangular grill |
| Built-in grills | Insert only if recessed, full frame if standalone | Measuring the counter cutout instead |
| Clearance | Add 1–2 inches of slack | Buying skin-tight for a “cleaner” look |
| Shape | Match cover shape to grill shape | Forcing a rectangular cover over trapezoid bodies |
Shape Matters As Much As Size
A cover sized correctly but shaped wrong still fits badly, because grills with extended shelves, side burners, or trapezoid bodies need a matching silhouette. A rectangular universal cover can leave gaps at the corners of a trapezoid body or bunch up around tall shelves. Lowe’s measurement guide puts it plainly: match the cover’s shape to the grill’s shape, not just its dimensions.
One more check on the label: a “60-inch” cover usually refers to width, not full footprint, so compare the cover’s listed width, depth, and height against your tape readings. If you would rather compare finished options side by side than decode sizing charts, this roundup of the best BBQ grill covers lays out tested picks by dimension and shape. Classic Accessories’ measuring guide covers the same protrusions-and-shelves logic.
The Three-Number Summary To Write Down
Write your width, depth, and height on a note and take it shopping — that note is the whole job. Add your chosen shelf position and whether your grill is rectangular, kettle, or trapezoid, and you have everything a cover listing asks for. Then apply two filters: the cover should clear your numbers by 1 to 2 inches, and its shape should echo your grill’s. Get both right and the cover slides on in one motion and breathes enough to keep rust away. Get either wrong and you will be back at the tape measure in a month.
FAQs
Do I include side shelves in the width?
Include them whenever they stay upright. If your shelves fold down, measure the grill in whichever position it will sit outside. Shelves that fold but are stored up count toward width; shelves stored down do not.
Should the lid be open or closed when measuring?
Closed, every time. Height is measured from the ground to the top of the closed lid. An open-lid reading can add several inches and leads to a cover that hangs loose and flaps.
Can I just buy by the cover’s size label?
Only after comparing the cover’s listed width, depth, and height against your own tape readings. A “60-inch” label typically refers to width, not the whole footprint, so a cover marked to fit your size can still be wrong in depth or height. Check all three numbers and the shape.
References & Sources
- Classic Accessories. “How to measure BBQ Grills” Supports measuring width, depth, and height with protrusions and fixed shelves included.
- Lowe’s. “How to Measure a Grill for a Cover” Supports shape matching and measuring fixed versus fold-down shelves in their stored position.
- Hunker. “How to Size a Grill Cover” Supports the 1–2 inch clearance guidance for breathability and airflow.