Best Broil King Grill Cover

Rain, sun, snow, and dust wear out a good grill faster than cooking does. The best Broil King grill cover keeps water off your burners and controls, shades the finish from fading, and stays put when the wind picks up. The trick is matching the right cover to your exact model, because Broil King sells different covers for different grills.

This guide walks through nine Broil King cover options, from Select covers for tight budgets to Premium covers with mesh venting and a longer warranty. You will also get a buyer’s checklist, measuring tips, and care advice so your cover lasts for years.

Quick Answer: The best Broil King grill cover for most owners is the Premium cover (68487) for Baron, Crown, and Signet 400-series grills, with water-resistant PVC, 900D polyester backing, mesh venting, and a five-year warranty. Budget pick: Select 67487. Upgrade pick: Premium 68488 for Baron 590 and 520. Confirm your exact model first.

Best Broil King Grill Cover Picks at a Glance

Cover	Key spec	Best for	Price range
Premium 68487 (top pick)	PVC with 900D polyester backing, mesh venting, 5-year warranty	Baron 490/440/420, Crown 490/440/420, Signet 390/70/320	85-110
Select 67487 (budget pick)	PVC with 500 x 300D polyester lining, 3-year warranty	Same 400-series grills on a smaller budget	65-85
Premium 68488 (upgrade pick)	Same Premium build, sized for the larger Baron 500 series	Baron 590 and 520
Premium 68491 and 68490/68492	Premium build for Regal and Sovereign XLS grills	Regal 490/440/420, 590, 690; Sovereign XLS
Select 67468	51 x 21 x 40 in. (130 x 53 x 102 cm) per one retailer	Gem 310, Royal 320 and 340	55-95
Select 67470	Select build for compact Monarch and Baron 320 grills	Monarch 390/340/320, Baron 320	60-80
Pellet grill covers (67064, 67066, 67065, 67069)	Select and Premium builds for Crown and Regal pellets	Pellet grill owners	50-100
Built-in Imperial covers (68591, 68592, 68590)	Premium build for built-in Imperial grills	Island and built-in installs	85-110
Keg cover (68360)	Premium cover for the Keg charcoal cooker	Keg 4000 and 5000 owners	60-85

Broil King Premium Cover 68487: Best Broil King Grill Cover Overall

Who it’s for: Owners of the popular 400-series gas grills who want the strongest cover Broil King makes for them.

The Premium line uses water-resistant PVC bonded to a heavy woven 900D polyester backing. Broil King lists mesh venting, hook and loop closures, blue accent stitching, reinforced seams, and molded rubber handles on its Premium covers. Venting matters because it lets trapped moisture escape instead of sitting on your grates and cart.

The manufacturer fit chart lists 68487 for Baron 490, 440, and 420, Crown 490, 440, and 420, and Signet 390, 70, and 320. One retailer lists the size as 58 x 21.5 x 46 in. (147 x 55 x 117 cm).

Key features:

• PVC with 900D polyester backing
• Mesh venting and reinforced seams
• Hook and loop closures and molded rubber handles
• Five-year warranty listed on the Broil King page

Pros:

• Best fabric and build in the Baron, Crown, and Signet range
• Vents reduce moisture buildup under the cover
• Rubber handles make it easier to pull off a snug cover

Cons:

• Costs more than the Select version
• Exact fit means it will not suit a different grill
• Dimensions vary by source, so confirm before ordering

Broil King Select Cover 67487: Best Budget Broil King Grill Cover

Who it’s for: Backyard cooks who want proper protection for a 400-series grill without paying for Premium extras.

The Select line uses a weather-resistant PVC outer shell with a 500 x 300D polyester lining, according to Broil King. It has hook and loop closures, polyester handles, and the Broil King logo screened on the front. The Select page does not mention venting, so expect less airflow than the Premium cover.

The manufacturer lists 67487 for Baron 490, 440, and 420, Crown 490, 440, and 420, and Signet-series grills, so it covers the same grills as the Premium 68487. The warranty listed for Select covers is three years.

Key features:

• Weather-resistant PVC shell, polyester lining
• Hook and loop closures
• Three-year warranty listed

Pros:

• Lower price than Premium
• Same exact-fit idea as the more expensive cover
• A smart pick for a covered patio

Cons:

• No mesh venting listed
• Polyester handles instead of molded rubber
• Shorter warranty than Premium

Broil King Premium Cover 68488: Best Upgrade for Baron 500 Series

Who it’s for: Owners of the larger Baron 590 and 520 grills who want Premium protection on a bigger frame.

The 500-series grills are wider, so they need their own cover. Broil King lists the Premium 68488 for Baron 590 and 520, with the same PVC and 900D polyester build, mesh venting, and five-year warranty described on the Premium page. A Select version, 67488, also exists for these models.

Prices for larger covers run higher. One retailer showed larger Premium covers in the 100-115 range, but did not tie those prices to a model number, so check the exact listing .

Key features:

• Premium PVC and 900D polyester build
• Mesh venting and reinforced seams
• Sized for Baron 590 and 520

Pros:

• Full Premium protection for the bigger grill
• Molded rubber handles
• Long warranty

Cons:

• Highest prices in the lineup after Imperial island covers
• Specific dimensions are not published on the Broil King page
• Only fits the 500-series Baron grills

Broil King Premium Covers for Regal and Sovereign XLS

Who it’s for: Regal and Sovereign XLS owners who want a cover made for their grill head and cart.

Broil King lists several Premium covers for this group. The Regal 690 uses 68490, the Regal 590 uses 68492, and the Regal 490, 440, and 420 share 68491. The Sovereign XLS 90 and XLS 20 also use 68491.

These grills tend to be larger and more feature-heavy, so a loose, mismatched cover leaves gaps for rain and wind. Use the model number on your grill’s rating plate, not just the series name, when you match a cover.

Key features:

• Premium build with mesh venting
• Model-specific sizing for Regal and Sovereign XLS grills
• Five-year warranty listed 

Pros:

• Made for the bigger grill bodies
• Vents help with condensation
• Reinforced seams hold up in wind

Cons:

• Dimensions not published on the Broil King page
• Item numbers repeat across different models, so double-check the fit chart
• Pricing not confirmed 

Broil King Select Cover 67468: Best for Gem and Royal Grills

Who it’s for: Owners of compact Gem 310 and Royal 320 or 340 grills.

This cover is listed for the Gem 310 and Royal 320 and 340. One retailer lists it at 51 x 21 x 40 in. (130 x 53 x 102 cm) and describes a water-resistant PVC shell with polyester lining, hook and loop closures, polyester handles, and a screened Broil King logo.

The same retailer page shows two different denier numbers for the lining (300D in the description and 900D in the specifications), so confirm the build with the seller if fabric weight matters to you .

Key features:

• Compact fit for smaller grills
• Hook and loop closures
• Screened logo on the front

Pros:

• Affordable for a small grill
• Easy to put on and take off
• Fits apartments and small patios

Cons:

• Retailer specs do not agree on lining weight 
• No mesh vents listed
• Does not fit any larger Broil King model

Broil King Select Cover 67470: Best for Monarch and Baron 320

Who it’s for: Owners of mid-size Monarch and Baron 320 grills.

Broil King lists 67470 for Baron 320 and Monarch 390, 340, and 320, with 68470 as the Premium option for the same grills. If you have a cover problem with a Monarch grill, the shelf position can matter, so check whether your side shelves are folded up or down when you measure.

The Select cover gives you the same basic protection as other Select models at a lower cost. A Premium 68470 adds venting and a longer warranty if your grill lives outdoors year-round.

Pros:

• Fits smaller mid-size grills
• Select pricing
• Premium upgrade available

Cons:

• No venting listed on Select
• Fit depends on shelf position 
• Limited published dimensions

Broil King Pellet Grill Covers: Crown and Regal Pellet

Who it’s for: Pellet grill owners who want to protect the hopper, controller, and chimney.

Broil King lists Select covers for its pellet grills: 67064 for Baron and Crown Pellet 400, and 67066 for Baron and Crown Pellet 500. Retailer listings also show Premium covers for the Regal Pellet line: 67065 for Regal 400 and 67069 for Regal 500.

A pellet grill has a hopper that holds dry wood pellets, and pellets swell and crumble when they get damp. A snug cover keeps rain off the hopper lid and off the controller. If you are still choosing a cooker, see our guide to the best pellet grills for beginners.

Key features:

• Select and Premium options
• Sized for hopper and chimney
• Select pellet covers listed in the 50-65 range at one retailer 

Pros:

• Keeps pellets and electronics drier
• Select version is budget friendly
• Premium option for year-round outdoor use

Cons:

• Pellet covers are model-specific
• Prices vary 
• Not interchangeable with gas grill covers

Broil King Built-In Imperial and Keg Covers: Best for Specialty Cookers

Who it’s for: Owners of built-in Imperial grills and Keg charcoal cookers.

Retailer listings show Premium covers for built-in Imperial grills: 68591 for Imperial 490 and Regal S420, 68592 for Imperial 590 and Regal S520, and 68590 for Imperial XLS. A built-in grill sits in an island, so the cover only needs to protect the grill head. For the Imperial 600 series built-in island, a Premium 68690 is listed.

Keg owners have their own Premium cover, listed as 68360 at one retailer and as a Keg 4000 and 5000 cover at another . A round charcoal cooker has a different shape, so a gas grill cover will not fit.

Pros:

• Made for unusual shapes
• Premium build on most listings
• Keeps built-in heads clean between cooks

Cons:

• Higher prices for island covers 
• Fewer published specs
• Limited retailer stock in some regions

How to Choose the Best Broil King Grill Cover

Use this checklist before you add anything to your cart.

1. Match your exact model number Broil King covers are exact fit. The manufacturer page lists them by model, so look at your rating plate first. A Baron 490 and a Baron 590 look alike but need different covers.

2. Premium or Select

• Premium covers use water-resistant PVC with heavy 900D polyester backing, mesh venting, molded rubber handles, and a five-year warranty.
• Select covers use weather-resistant PVC with a lighter polyester lining, polyester handles, and a three-year warranty.

Premium costs more but suits a grill that lives outside through snow, summer sun, and heavy rain.

3. Venting Mesh vents let moist air out. Without them, condensation can build up under any cover on a warm day after a cold night.

4. Closures and handles Hook and loop closures help keep wind from lifting the cover. Molded rubber handles are easier to grip when the cover is wet.

5. Measure your grill Measure width with side shelves in the position you leave them, depth front to back, and height to the top of the lid handle. Compare these numbers with the cover listing, not just the series name.

6. Warranty The Broil King page lists five years for Premium and three years for Select covers .

Pitmaster Tip: Before you lay a cover over a grill you use often, run a quick cleanup. Brush the grates while they are still warm, wipe grease from the lid, and let the grill cool until the metal is cool to the touch. Cleaner grates mean fewer smells and less sticky residue when you cook again.

Common Mistake: Putting a cover on a grill that is still hot or damp. PVC and polyester are not made to touch hot metal, and a wet grill under a cover invites musty smells and rust. Wait at least 30 minutes after a high-heat cook and make sure everything is dry.

If you are still learning your cooker, our guide on how to start a grill covers the safe way to light it. Always take the cover completely off before you light the grill, and never leave it draped over the cart while the burners are on.

How We Picked the Best Broil King Grill Cover

We want to be direct: this guide compares published specs and listings, not lab tests, so we did not run weather or wear tests. Here is what we weighed:

• Fit: whether the cover is listed for your exact model
• Fabric: PVC and polyester weight, and whether the lining is clearly stated
• Venting: mesh vents on Premium covers
• Handles and closures: molded rubber versus polyester, hook and loop closures
• Warranty: the length listed by the manufacturer
• Value: price range for the size and build
• Availability: whether the item showed in stock when we checked

Where a listing was missing a spec or two sources disagreed, we marked it . Add your own photos and measurements next to each pick as you test them.

How to Make Your Broil King Cover Last

A good cover can last for years if you treat it well. A few habits make a big difference.

• Let the grill cool first. Cover only when the metal is cool and dry.
• Clean the cover itself. Wipe off dirt, pollen, and bird droppings with warm water and mild soap. Rinse well and let it air dry fully before you put it back on.
• Use the vents. On Premium covers, make sure the mesh vents are not blocked by leaves or snow.
• Secure the closures. Fasten the hook and loop straps so wind cannot work the cover loose.
• Remove it before heavy rain pools. Water can sit in folds on a flat lid, so shake it off.
• Store it clean. If you put the grill away for winter, fold the cover dry and keep it somewhere dry.
• Check the seams. Replace the cover when seams split or the fabric cracks. That is cheaper than repairing a rusty cooktop.

If you want to compare other brands before you commit, our roundup of heavy-duty grill covers covers more options and fabric choices.

Gas grill owners also know that the side burner is one of the first places moisture finds its way in. Our explainer on the side burner on a gas grill shows why that area deserves a snug fit. If you are cooking for a crowd, see our summer BBQ party tips for ways to get the grill ready fast.

Cooking days go better when your grill is ready. Running a pellet grill at 225-250°F (107-121°C), for example, is easier when pellets stay dry and the controller is clean, a point worth remembering before you cook ribs on a pellet grill. At the other end, gas grills at 450-500°F (232-260°C) for searing need a cool-down before the cover goes back on.

FAQ

What is the difference between Premium and Select covers?

Premium covers use water-resistant PVC with a heavy 900D polyester backing, mesh venting, molded rubber handles, and a listed five-year warranty. Select covers use a weather-resistant PVC shell with a lighter polyester lining, polyester handles, and a listed three-year warranty. Premium costs more but gives better airflow and a longer warranty.

Are Broil King covers waterproof?

Broil King describes its covers as water-resistant or weather-resistant, not waterproof. The PVC shell sheds rain and snow, and Premium covers add mesh venting so moisture can escape. Standing water can still collect in folds, so shake the cover off after heavy rain and let it dry fully.

Which cover fits a Broil King Baron 490?

The Broil King page lists Premium 68487 and Select 67487 for Baron 490, 440, and 420 grills. These same item numbers also fit Crown 490, 440, and 420 and several Signet models. Always check your model number on the rating plate before you order, because the larger Baron 590 and 520 use different covers.

Do Broil King grill covers have vents?

Premium covers list mesh venting that lets moist air escape and helps limit condensation. The Select covers on the Broil King page do not mention venting. If your grill lives outside through humid summers or freezing winters, Premium is the safer choice for reducing moisture buildup under the cover.

Can I put the cover on a warm grill?

It is best to wait. PVC and polyester covers are not made to touch hot metal, and trapped heat and moisture can damage both the cover and the grill. Let the grill cool until the metal is cool to the touch, then cover it. Check your Broil King manual for its guidance.

How do I measure my grill for a cover?

Measure width with the side shelves in the position you usually leave them, then depth front to back, then height to the top of the lid handle. Compare these numbers with the listing for your model. Since Broil King covers are exact fit, your model number matters more than the measurements.

Conclusion

The best Broil King grill cover is the one made for your exact model. For most 400-series gas grill owners, the Premium 68487 is the top pick thanks to its 900D polyester backing, mesh venting, and five-year warranty. The Select 67487 is the budget-friendly choice for covered patios, and the Premium 68488 steps up protection for the bigger Baron 590 and 520.

Check your rating plate, measure with the shelves how you actually leave them, and cover the grill only when it is cool and dry. Do that, and the best Broil King grill cover will keep your grill ready for the next cookout.