First POST by another confessed lurker. I can't express my appreciation enough for the posts on the 2008 reds. I used the info to get a 2008 4 burner from HD for $669 brand new in the box. Floor models were offered with 10% discount but were seriously banged up.
It took about an hour to put together by myself last night. My thoughts on packaging, assembly and construction:
Thanks for the heads up from many of you on inspecting before buying. The top of the grill in the first box had a pretty bad ding.
Second one looked pristine (noticed the word looked). After unpacking noticed that side panel was bent and back panel had popped out along top edge. There was also a big flat panel inside under the grill that had popped loose and fell down when I pulled the boxes of parts out. It is only held in by two screws in front and two tabs that fit into the back. Had to take it out and bend tabs back to reattach.
Treat this thing with kid gloves until you get the side shelves firmly attached. Whatever you do, keep upright, DO NOT TIP. Apparently the top and bottom are very rugged but the panels between are really flimsy until you attach the side shelves. Mine apparently got tilted at some point and twisted the top a little to the left. This is what forced the back panel to pop out. The back panel isn't fully attached until you connect the side shelves using 1 1/1" screws that go from shelf >> side >> into back panel. So I used a little percussive persuasion (read hammer) and got it assembled. WOW, it's like a different grill. The thing is solid as a rock once you bolt everything together. The only thing with any give at all is the side burner cover. Everything else is rock solid.
Another thank you goes out right here for the ones that pointed out the rerouting of the tank sensor cable. Went on Char-Broil and checked the official FAQ and took care of that.
Only real disappointment is the flimsy tank sliding shelf locking pin. I'll have to upload a pic. Nothing to get worked up about, but considering the way everything else is put together, you'd think they would have done it better.
Fired it up and enjoyed the burning oils smell. Left all 4 burners on clean for about 20 minutes and LCD panel said 414 F but lid says 325 F. I plan on working on it when I get home today and making sure everything is good and I didn't trip the safety. I have pics on my camera at home and hope to upload some by this weekend. Posting this from work :-)