Low prices and year-round grilling have spawned record grill sales as patios and decks morph into outdoor-living space. But rising costs for raw materials such as stainless steel could mean higher prices this year.

Overseas manufacturing, mostly in China, is one way makers are trying to hold the line. More brands are also starting to use stainless only for trim or specific parts. You’ll also find painted steel more common on lower-priced grills.

“As the price goes below $500, it’s difficult to make an all-stainless-steel grill,” explains Alex Gafford, director of research and development for Char-Broil, the biggest U.S. brand. Indeed, only one of the grills we tested at that price was made entirely of stainless.

We ran 30 grills sized from portable to large through weeks of testing and cooked up more than 160 pounds of fresh beef, chicken, and fish. We found a model for as low as $300 that offers high performance, good value, and even some stainless steel. A number of companies are also pushing grills priced into the thousands as they chase bigger profits. But as our battery of tests revealed, a higher price tag doesn’t guarantee better grilling in your backyard. Here are the details:

Top names get beaten. The $1,750 Weber Summit S-650 and the $3,200 Viking T Series we tested include high-end features and materials such as a smoker burner and a smoker box, a rotisserie spit and motor, and stainless steel. But they couldn’t outperform the $800 Kenmore 16237 in our grilling tasks, especially at low temperatures.

High-end features trickle down. Even if prices aren’t dropping, you’re likely to find more premium features--side burners, rotisseries, high-quality cooking grates--on lower-priced grills.

On midpriced and upper-tier grills, some brands are trading traditional gas burners for high-powered infrared versions in a move to add a feature without necessarily having to boost the price. (Infrared burners also use gas.)


HOW TO CHOOSE

The Ratings  include liquid-propane models that range from portables to large models. See Types to understand what you get for your money. Then keep these tips in mind:

Don’t be wowed by Btu. Brands tout the British thermal units per hour (Btu/hr.) rating. But that figure indicates how much gas is used, not grill temperature, so a higher number doesn’t guarantee faster heating or improved searing. Indeed, the Brinkmann Pro and other high-Btu models are not top performers.

Test its metal. Look for 300-series stainless. It’s a higher grade than the 400-series, and as our tests to simulate weather exposure demonstrated, it should fight corrosion better. To identify grills made of lower grades, which are usually magnetic, take a magnet when shopping. Note that many grills mix stainless types.

Case the cart. Give the grill a gentle bump from several angles to see if it tips. The more stable the grill, the safer it is. Inspect the cart, firebox, and shelves for sharp edges and corners. Be sure the curve of a handle doesn’t place your fingers or knuckles too close to the lid--you could get burned when cooking. (Note that metal handles can get hotter than wooden or plastic ones.) Also look for a sliding drawer for the fuel tank, which facilitates using and changing the tank.

Consider flare-ups. Some flaring is normal with fatty foods. But the greater the distance between the grates and where the grease lands, the fewer sustained flare-ups. The BBQ Grillware, Char-Broil Designer Series, Coleman, Ducane Affinity 4200, Frigidaire, and Viking flared up more than others. Look for a removable grease tray or pan, which you can clean to prevent buildup.

Rate the grates. Grills with heavier stainless-steel or porcelain-coated, cast-iron grates do a much better job searing than thinner steel ones.