grease is leaking from the bottom of my grill cabinet, not going into the bucket. where's it coming from?

Diagnosis

The leak is occurring because the grease management system is failing to channel runoff into the collection bucket, causing it to pool in the cook chamber and overflow through the seams of the chassis. On the Pit Boss Pro Series 1150, this typically happens due to "grease dams"—accumulations of carbonized food debris and solidified fats that block the narrow drainage channel. When this happens, the grease doesn't just sit still; it finds the path of least resistance, which is usually the gap between the heat deflector/cook chamber and the lower cabinet shell, leading to those frustrating drips on your patio. Another common cause is a misalignment of the grease tray or a failure of the seal where the tray meets the drain hole. If the tray has shifted slightly during a cleaning session or if the bucket is overfilled, the grease will bypass the collection point entirely. To confirm this, look at the bottom of the cook chamber (above the tray); if you see a thick layer of standing oil or "sludge" instead of a clean slope toward the drain, you have a blockage. If the tray is empty but the cabinet is leaking, the leak is occurring upstream of the tray.

How to Fix It

To stop the leak, you must clear the drainage path and reset the collection system. Follow these steps precisely:

1. Power down the grill and allow it to cool completely. Remove the grill grates and the heat deflector plate to gain full access to the bottom of the cook chamber.
2. Slide out the grease collection tray and remove the grease bucket. Inspect the tray for any warping or bends that might be preventing it from sitting flush against the drain port.
3. Locate the drain hole at the rear of the cook chamber. Use a heavy-duty pipe cleaner or a 1/8-inch steel wire to poke through the drain hole. Push the wire firmly to break through any solidified "fat plugs" that have formed in the narrow channel.
4. Using a degreaser or a mixture of warm water and dish soap, scrub the slope of the cook chamber floor. Ensure there are no charred food remnants creating a dam that diverts grease away from the hole.
5. Reinsert the grease tray, ensuring it is pushed completely to the back of the unit. Confirm that the tray's intake aligns perfectly with the drain hole.
6. Insert a fresh, empty grease bucket and verify that there is a clear, unobstructed path from the cook chamber, through the tray, and into the bucket.

If That Didn't Work

• Check the chassis seams for gaps. If the leak persists despite a clear drain, the sealant between the cook chamber and the cabinet may have degraded. Apply a high-temperature RTV silicone sealant (rated for at least 500°F) to the exterior seams where the cook chamber meets the lower cabinet to plug any structural leaks.
• Inspect the heat deflector for "pooling." If the deflector plate is slightly warped or not seated correctly, grease can pool in the center and overflow the sides of the chamber rather than flowing toward the rear drain. Ensure the plate is level and seated firmly on its supports.
• Verify the bucket seal. If you are using a third-party bucket or if the original bucket is cracked, grease may be leaking from the bucket itself rather than the grill. Replace the bucket with a genuine Pit Boss replacement part to ensure a vacuum-tight fit.
• Deep clean the "drip zone" using a pressure washer or a steam cleaner. Sometimes a layer of hardened carbon builds up under the tray that cannot be reached by a wire, effectively creating a new floor that diverts grease toward the cabinet walls.

Heads Up

• Empty the grease bucket every 3-5 cooks. An overfilled bucket causes grease to back up into the tray, which is the primary cause of cabinet leaks.
• Avoid using aluminum foil to line the bottom of the cook chamber. While it makes cleanup easier, foil often blocks the drain hole entirely, forcing grease to leak through the chassis.
• Perform a "burn-off" at 450°F for 15 minutes after heavy fatty cooks (like brisket or ribs) to liquefy any remaining grease in the channels, allowing it to flow into the bucket before it solidifies.
• Check the tray alignment every time you change the bucket; a 1/4-inch shift in the tray's position is enough to cause a significant leak.