Pit Boss · Accessories
Pit Boss Grill Cover Selection: Model-by-Model Guide
A fitted Pit Boss cover is the single highest-ROI accessory — doubles grill life in humid climates, cuts rust risk by half, and takes 20 seconds to install. The gotcha is sizing: the Austin XL cover doesn't fit the Navigator 850, the Pro Series needs a shelf-aware cut, and the portable needs a soft bag not a cover. This is the matching guide.
By Reed · Updated November 9, 2026
What you need
- Tape measure (for aftermarket confirmation)
- The grill's model number (serial plate)
Which cover fits which model
- Austin XL 1000
- 73731 (official) or any 60" x 24" x 48" cover
- Classic 700
- 73161 (official) or 48" x 24" x 48" cover
- Lexington 500
- 40" x 24" x 48" cover
- Navigator 850
- Navigator-specific — factory shelf cutouts
- Pro Series II 600
- Pro Series shelf-aware fit
- Pro Series 1600 Elite
- Elite-specific — wider and deeper than Austin
- Portable (PBV3)
- Soft travel bag, not a cover
Step by step
Find your model and serial plate
Serial plate is usually on the back of the hopper or inside the lower cart door. Record the model number and the rear-to-front, side-to-side, and height dimensions.
Match to the official Pit Boss cover part number
Official covers are sized exactly to each model with shelf cutouts. Use pitboss-grills.com (with the dash) to confirm the current part number.
Or choose an aftermarket cover with correct dimensions
Aftermarket covers work if dimensions match. Prioritize heavy-duty fabric (600D polyester or better) with wind straps and air vents.
Install the cover over a cool grill with the lid closed
Covers over hot grills can melt the cover lining. Always cool first. Drape from the hopper side first, work toward the chimney.
Secure wind straps or clip under the cart
In windy locations, unsecured covers are gone by morning. Use the included strap or a bungee under the cart.
Common mistakes
- Buying a universal cover. Universal covers rarely fit Pit Boss shelf cutouts, so water pools where the shelf pokes out. Model-matched beats universal.
- Covering immediately after shutdown. Heat retained after shutdown can scorch the cover lining — allow 2 hours cool-down before covering.
Hands-on tips
- In humid climates, pair the cover with a desiccant pack INSIDE the grill (removed before cook) to pull moisture out of the cook box overnight.
- Wind vents in the cover prevent the "parachute" effect in high wind — look for mesh panels on the top.
- A cover with a reinforced seam over the chimney lasts 3x longer than one without.
Questions people ask
Do I need the official cover or is aftermarket fine?
Aftermarket works if dimensions match. Official covers have model-specific shelf cutouts that aftermarket covers lack.
How often should I replace the cover?
Heavy-duty covers last 3 to 5 seasons in moderate climates, 2 to 3 seasons in coastal or high-UV climates.
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