My wife and I bought a Thermos Quick Start grill last year, one with a porcelain cooking grid. I have been very particular about taking care of it - seasoning, cleaning, etc. - because my wife's grill (before we got married) had more rust on it than a junkyard.
But here we are just about one year later, and the cooking grid is rusting, first in the back center over a hot spot, then slowly spreading to cover just about the whole center of the cooking surface. I am at a loss as to why.
Don't know if any of the following would be causes or have an impact: we've used the grill at least weekly since we bought it (including through the winter, though not during the Valentine's Weekend Big Snow), I season the grill with a fine mist of canola or other vegetable oil sprayed on when I first light the grill, and put another coating on after the grill has cooled a bit (it softens some of the ashy gunk for removal the next time), the grill cover was shredded by Spring and we went about 5-6 weeks without a cover, during the wettest April and May in memory (28 out of the 31 days in May we had rain in Baltimore), for cleaning I stopped using the synthetic scrunge-type pad and have been using a brass soft-bristle brush.
I've approached this grill as I would a cast iron skillet or other valuable stove pan, wanting to keep it well-maintained and seasoned, not abused. But I worry I've abused it in the process. I don't think the brush has scraped through the porcelain coating because the rust is only in one (spreading) patch rather than across the cooking grid especially in the spots where food has been cooked.
Any help or suggestions for getting rid of the rust would be greatly appreciated!