Seriously, I deep cleaned my Weber last month and the thing looks like it sat in the ocean. Live in the midwest so the humidity is killer. Tried that rust converter stuff but it keeps coming back. Am I doing something wrong or is this just part of owning a grill?
Check if your grill's paint is compromised. Sometimes if the coating gets scratched the rust spreads fast underneath. I had to repaint mine with high heat paint and now it's way better.
This is exactly why I moved away from charcoal to gas. One less thing to worry about with metal rusting everywhere.
Man I feel this. My Weber looks like it's been through a war after two months. Started spraying it down with some food grade mineral oil after cleaning and that seems to help slow the rust.
Have you tried those grill grates cleaner products? Not the brushes but the actual chemical stuff? Changed my life honestly.
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Where do you live? Coastal areas are brutal on grills. I switched to a stainless steel cover and it made a huge difference. Also started using a grill brush after every cook instead of waiting for deep cleans.