Cause

The Flat Tops are made from Mild Steel that contains iron. When iron is exposed to water in the form of rain or humidity it reacts with oxygen in the air to form rust. Seasoning your Flat Top is the most important step in protecting the steel from rust along with a fresh coat of oil after each use before storing. If you live in a humid area or near the ocean it may be necessary to store your Flat Top indoors during extended periods when it will not be in use. Even the best layer of seasoning will not prevent rust from forming in these environments.

Solution

If your Flat Top has developed some rust, don't worry! It's a simple fix to get it looking like new. Rust only forms on the surface so scraping it away leaves fresh steel that's ready to re-season like new. Here's how to do it:

1. Place your Flat Top on the grill and heat on medium high for 20 minutes. This will loosen the rust from the steel making it easier to remove.
2. Let the Flat Top cool. Use a scraper to scrape the entire surface to remove any rust that has formed.
3. Spread 4-5 tablespoons of oil across the surface of the Flat Top and scrub it down with a grill stone. If you don't have a grill stone, use steel wool or medium grit wet-or-dry sandpaper.
4. Wipe the Flat Top clean with a cloth or paper towels.
5. Drip another 3-4 tablespoons of oil and wipe the griddle down again. Repeat until all signs of rust are gone.
6. Season the Flat Top to create a protective coating that avoids rust. Any cooking oil works, but we prefer Flat Top Oil or extra virgin olive oil. 
7. When you’re done seasoning, spread another 3-4 tablespoons of cooking oil across the surface for an extra protective layer. This blocks contact between air and water with the Flat Top – preventing the formation of rust.

Remember to store your Flat Top in a cool, dry place to protect the steel from corrosion.