Best Broil King Gas Grill: The Underdog, Tested
Best Broil King Gas Grill: The Underdog, Tested
I've spent 12 years judging BBQ and the last 8 cooking on a Weber Genesis that's survived two burner replacements and a Chicago winter that would make a polar bear cry. When people ask me about Broil King, they usually ask it like a confession. Like they're admitting they bought a Hyundai when everyone told them to get a Toyota. Here's the thing: I've cooked on three Broil Kings this season, and the brand keeps showing up where I don't expect it.
The Broil King Regal 500 is the best gas grill most people haven't considered, because it out-cooks comparably priced Webers on searing and heat distribution while costing less than the Genesis line.
Pros
- Dual-tube burners run the full front-to-back length, which means no cold zones across the cooking surface
- The 500-series firebox is heavy-gauge steel with a 10-year warranty that actually covers rust-through
- Rotisserie motor included in the box, not sold as a $150 add-on
- Even heat across all three burners, verified with my dozen-burger test
Cons
- Assembly took me 2.5 hours and the instructions read like they were translated from a language that doesn't have words for "left" and "right"
- The igniter died in week three. I used a lighter. So did three buyers I talked to.
- The warming rack is positioned too close to the lid, so it reflects heat down onto your food if you're not careful
Compared to the Weber Genesis
The Genesis E-325s runs about $799. The Broil King Regal 500 runs about $699. Same ballpark, different philosophy.
Weber's burner layout is a straight tube across the middle. Broil King uses a dual-tube design where gas flows through two parallel tubes that merge at the end. That changes the heat map. My burger test showed a 10-degree spread across the Broil King's cooking surface. The Genesis put down a 15-degree spread. Both are good. The Broil King is better.
The Genesis has better resale and a bigger parts network. Weber flavorizer bars are at every hardware store in America. Broil King parts you'll order online. That matters if you're the type who needs a part same-day.
The Napoleon Rogue 525 sits at $749 and has the infrared sear burner, which the Broil King doesn't have. If you want that steakhouse crust and you're willing to pay an extra $50, the Napoleon wins that specific fight. But the Napoleon's firebox is lighter gauge steel, and I've seen the paint flake on two-year-old units.
Design
The 500's firebox is the first thing I checked. It's 7-gauge steel on the hood and 10-gauge on the body. That's thicker than the Weber Genesis and noticeably heavier when you lift the lid. The whole grill weighs 175 pounds. You're not moving this thing alone, and I mean that as a compliment.
The cooking surface is 500 square inches, which is enough for 24 burgers or a full brisket if you're careful about placement. The grates are 9mm stainless steel rods. They're not cast iron, so you lose a little heat retention, but they sear fine and they won't rust out in two winters.
The dual-tube burners are rated at 30,000 BTUs across three burners. That's not the highest number on the market, but BTU ratings lie. I've cooked on a 60,000 BTU grill that couldn't sear a steak because the heat escaped through a poorly sealed lid. The Broil King holds heat because the firebox is sealed properly. The lid closes with a solid thunk, not a rattle.
I tested the rotisserie with a 6-pound chicken. The motor is quiet, the spit is balanced, and the infrared rear burner held 350 degrees for an hour without a flame-out. That's a real feature, not a box-checking exercise.
Performance
I ran the standard routine: a dozen burgers for evenness, a full brisket for heat stability, a chicken for flare-ups.
The burgers went on at 450 degrees. Left rear ran 460. Right front ran 450. That's a 10-degree spread. For comparison, the Char-Broil I tested last month had a 50-degree spread. The Broil King is the best heat distribution I've seen outside of a Napoleon with the infrared burner running.
The brisket went on at 250 degrees. I closed the lid and didn't touch it for 40 minutes. When I opened it, the temp had drifted to 255. That's a 5-degree swing. My Genesis drifts 10. The Broil King holds temperature better than anything I've tested in this price range.
The chicken test exposed the flare-up issue. The drip tray is adequate, but if you're cooking a fatty bird at high heat, you'll get flare-ups on the left side. That's the burner layout. The left burner is closer to the grease channel. I learned to put a drip pan under the bird and move on. It's not a dealbreaker, but it's a quirk.
Recovery time: after I opened the lid to flip the burgers, the Broil King got back to 450 in 90 seconds. My Genesis takes 2 minutes. That's a measurable difference, and it matters when you're cooking for a crowd.
Durability
I've only had the Regal 500 for four months. That's not a durability test. But I've talked to owners who've had theirs for years, and I've read the complaint patterns.
The firebox warranty is 10 years. That's the real deal. Broil King covers rust-through on the main body, not just parts. Weber does the same, but Broil King's terms are cleaner. No "reasonable use" language that gives them an out.
The paint is the weak point. I've seen photos of Broil Kings with paint flaking on the hood after two years. It's cosmetic, not structural, but it's annoying on a $700 grill. Weber's porcelain enamel finish holds up better. If you're the type who covers your grill every night, this won't matter. If you leave it out in the weather, expect some flaking.
The igniter is junk. I've heard this from multiple owners. "Used it twice, then bought a lighter." That's the standard complaint. Broil King ships a piezo igniter that dies in the first month. It's a $5 part and it's the most common warranty claim. Plan for it.
Value
The Regal 500 at $699 works out to about $0.19 per day if it lasts 10 years. A $200 Char-Broil that lasts two years costs $0.27 per day. The cheap grill isn't cheaper. That math holds.
You get the rotisserie motor included, which is a $150 value on a Weber. You get the 10-year firebox warranty. You get the best heat distribution I've measured in this price range. The trade-off is the paint quality and the igniter.
The Regal 500 is the best value in the $600-$800 range. The Napoleon Rogue 525 has the infrared burner, which is a better searing tool, but you pay $50 more and you get a lighter firebox. The Weber Genesis has better resale and easier parts access, but it costs $100 more and doesn't include the rotisserie.
Should you buy it?
If you want a grill that sears evenly, holds temperature, and comes with a rotisserie motor without paying extra, yes. Buy the Broil King Regal 500. If you need a steakhouse crust from an infrared burner, buy the Napoleon. If you want the safest choice with the biggest parts network, buy the Weber. But know that you're paying for the name on the hood, not a better grill.
I've got a 12-pound brisket going on mine this weekend. The Broil King earned that cook.
Updated with new assembly notes and igniter data. I'm testing the Broil King Signet 400 next to see if the budget line holds up. That review is coming in a few weeks.