Same experience as Hill and Think. Are you sure your grill is dry when you put the cover on? One other issue that I alluded to before--the big boxes--Home Depot and Lowes--get different Weber grills than the local hardware stores sucg as Bradley's and Aubuchon. The local guys are more expensive, but it is a better product. I do not know if that extends to rust, just a guess. Most importantly--if you ever have any problem with a Weber, call their 800 number 365 days. They are amazing, maybe the best customer/warranty service in any business.
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