The Broil King Grill Guide: Choosing the Right Model for Your Space

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Selecting an outdoor cooker requires balancing patio footprint against heating capacity, burner configuration, and everyday maintenance. Backyard cooks evaluating broil king gas grills alongside dedicated wood-fired hardware frequently weigh whether a compact three-burner cooker provides enough primary grate area for weeknight dinners and weekend guests, or whether stepping up to an expanded multi-burner station justifies the additional yard space. Navigating specialized heat retention components, grease vaporization systems, and modular accessories makes it easier to pinpoint the best broil king grill for your outdoor entertaining routines.

The manufacturer arranges its cooking platforms into distinct tiers based on cooking volume, cart architecture, and fuel compatibility. Entry-level compact models use space-saving pedestal bases, mid-tier editions introduce enclosed storage cabinets, and flagship lines supply broad multi-burner surfaces with hybrid smoking possibilities. Dedicated wood-pellet stations provide digital automated smoking, while precision accessories transform existing fireboxes into artisan baking ovens. This comprehensive broil king grill comparison examines the specifications and structural differences across the catalog so you can quickly decide which broil king grill to buy.

Criteria matrix What each model in this report is credited with

Rows are the criteria that come up in the pros and cons listed for this lineup. A check means the criterion is named in this report’s write-up of that model; a dash means it is not. Criteria that apply to every model, or to only one, are left out because they separate nothing.

Criterion	Broil King 865364 Crown 8.8/10	Broil King 814954 Gem 9.0/10	Broil King 824154 Royal 8.8/10	Broil King 675144 Baron 8.6/10	Pizza Stone for Monarch 8.6/10	Pellet Grill by Broil 9.2/10
Stainless steel Dual-Tube	✓Named	✓Named	✓Named	✓Named	Not named	Not named
Cast aluminum cookbox	✓Named	✓Named	✓Named	Not named	Not named	Not named
Cast iron cooking	✓Named	Not named	✓Named	Not named	Not named	✓Named
Side shelves	✓Named	✓Named	✓Named	Not named	Not named	Not named
Auxiliary side burner	✓Named	✓Named	Not named	Not named	Not named	Not named
Enclosed cabinet	Not named	✓Named	✓Named	Not named	Not named	Not named
Limited lifetime	✓Named	Not named	✓Named	Not named	Not named	Not named
Cookbox warranty	Not named	✓Named	✓Named	Not named	Not named	Not named
Criteria named	6 / 8	6 / 8	7 / 8	1 / 8	0 / 8	1 / 8

Built from the wording of this report, not from a bench test. A dash is not a fault: it only means the write-up does not mention that point for that model. Scores next to each model are out of 10, based on listed specifications and buyer feedback.

Broil King Grills Lineup at a Glance

The Models in Detail

Broil King 865364 Crown S 440

Best for: Large family cookouts requiring active side searing

Pros

• Stainless steel Dual-Tube burners
• Reversible cast iron cooking grids
• Dedicated 10,000 BTU side burner

Cons

• Substantial footprint on compact decks
• Higher overall assembly weight

The Broil King 865364 Crown S 440 serves outdoor cooks who require substantial grilling estate paired with independent side-pan cooking capability. This four-burner propane cooker offers 630 square inches of total cooking area, partitioned into a 460-square-inch primary cooking surface and a 170-square-inch stainless steel warming rack. Its firebox houses four stainless steel Dual-Tube burners generating 40,000 BTUs across the main chamber, accompanied by a 10,000 BTU side burner located on the left shelf for boiling sauces, simmering glazes, or frying side dishes without heating up the kitchen indoors.

Cooking performance on the broil king crown s 440 relies on heavy-duty three-position cast iron cooking grids that allow users to alternate between a pointed edge for steakhouse sear marks and a grooved channel that gently bastes delicate items. Beneath the grids, the full-coverage stainless steel Flav-R-Wave cooking system vaporizes falling juices to infuse barbecue flavor back into the meat while shielding the burners. Drop-down side shelves keep prep space accessible while folding away for off-season storage, and the assembly is compatible with the exact-fit 67487 cover. A cast aluminum cookbox is protected by a limited lifetime warranty, supported by a 10-year warranty on the Dual-Tube burners, a 5-year warranty on the Flav-R-Wave system, and 2 years on remaining components.

This model is built for family gatherings and backyard barbecues where simultaneous multi-zone cooking is an advantage. Its four burners and auxiliary side burner satisfy large-capacity grilling, yielding ground to smaller units like the Royal 320 only when patio width is strictly constrained.

Broil King 814954 Gem 310 Shadow

Best for: Apartment balconies and space-restricted patio cooks

Pros

• Compact pedestal cart design
• Durable cast aluminum cookbox
• Drop-down resin side shelves

Cons

• Shorter burner warranty coverage
• No auxiliary side burner

Built for space-constrained balconies, townhome patios, and compact decks, the Broil King 814954 Gem 310 Shadow packs full-grade heating technology into an efficient footprint. The unit provides 430 square inches of total cooking space, combining a 295-square-inch primary cooking grate (listed as 300 square inches in the product summary) with a 135-square-inch porcelain-coated warming rack. Three stainless steel Dual-Tube burners deliver 24,000 BTUs, ensuring concentrated heat distribution across the non-stick cast iron grids.

The engineering of the broil king gem 310 shadow centers around a cast aluminum cookbox supported by a black powder-coated pedestal cart. Drop-down resin side shelves reduce the overall footprint when the unit is stored, while reliable electronic ignition starts the three burners promptly. When evaluating small-format cookers alongside entries like a traditional charbroil gas grill, the Gem distinguishes itself with durable cast aluminum casing rather than stamped sheet metal. It weighs 68 pounds, works with exact-fit covers 67470 and 67468, and includes a 10-year cookbox warranty, a 5-year burner warranty, and a 2-year warranty on remaining parts.

Urban cooks, couples, and small households who want high-heat searing capability in a small footprint will find this model ideal. It surrenders total square inches and enclosed cabinet storage to the Royal 320, but remains unmatched for manageable dimensions and straightforward mobility.

Broil King 824154 Royal 320 Shadow

Best for: Suburban backyard grilling with concealed propane storage

Pros

• Fully enclosed cabinet base
• 30,000 BTU Dual-Tube burners
• Limited lifetime cookbox warranty

Cons

• Lacks auxiliary side burner
• Single main cooking chamber

The Broil King 824154 Royal 320 Shadow bridges the gap between compact cookers and full-sized barbecue stations by combining a three-burner layout with an enclosed cart. Offering 500 square inches of total cooking area, the layout incorporates a 330-square-inch primary cooking space and a 170-square-inch porcelain-coated warming rack. Three stainless steel Dual-Tube burners generate 30,000 BTUs, providing sufficient thermal output to handle rapid heat recovery after lid openings.

Thermal stability is anchored by the deep cast aluminum cookbox, which isolates the cooking chamber from outside breezes. Much like the thermal retention sought by cooks examining a char-broil infrared grill, the broil king royal 320 shadow uses its full-coverage stainless steel Flav-R-Wave system to eliminate hot spots and vaporize drippings across the grates. Heavy-duty cast iron cooking grids retain heat for clean sear marks, while drop-down side shelves provide immediate staging area for tools and platters. The enclosed cabinet base conceals the fuel tank behind a clean matte black exterior. Coverage includes a limited lifetime warranty on the cookbox, 10 years on the Dual-Tube burners, 5 years on the Flav-R-Wave system, and 2 years on parts and paint, with cover 67470 offering tailored weather protection.

Homeowners seeking a tidy outdoor aesthetic will appreciate the enclosed cabinet that hides the propane cylinder. The Royal 320 serves as an upgrade over the Gem 310 for buyers wanting more cooking surface and burner power, while conceding total capacity to four-burner options like the Crown S 440.

Broil King 675144 Baron 590 Pro

Best for: Entertainers wanting high capacity and hybrid smoking

Pros

• Solid stainless steel V-Grids
• Modular pellet-ready architecture
• Rotisserie and side burners included

Cons

• Pellet module kit sold separately
• Requires large patio footprint

Designed for large-scale outdoor cooking and custom fuel versatility, the Broil King 675144 Baron 590 Pro represents the high-capacity apex of the brand’s freestanding gas lineup. This cooking platform boasts 780 square inches of total cooking space driven by five stainless steel Dual-Tube burners generating 45,000 BTUs. In addition to the broad primary grate area, the station incorporates an integrated commercial-style side burner and a rear rotisserie burner. Blue LED illuminated control knobs accent the matte black finish, offering clear visual feedback during evening grilling sessions.

A notable feature of the broil king baron 590 pro is its pellet-ready modular capability. Operating out of the box on standard propane, the firebox is engineered to accommodate the iQue Pellet Fuel Kit (SKU 675001, sold separately) to transform the cooker into a wood-fired smoker. The primary grates are reversible solid stainless steel V-Grids, featuring a pointed edge for high-temperature searing and an inverted V-channel to capture drippings for continuous meat basting. The full-coverage Flav-R-Wave system handles vaporization beneath the grates, and a built-in thermometer assists with chamber temperature tracking. The entire grill carries a 15-year top-to-bottom warranty supported by a 15-year European Union spare parts availability duration. Catalog dimensions list 4 inches deep by 4.1 inches wide by 18.5 inches high, reflecting crated component specifications rather than the full assembled footprint.

This cooker is suited for ambitious hosts who regularly prepare food for large groups and desire rotisserie roasting alongside standard grilling. Its modular architecture also appeals to owners who plan to introduce wood smoking without investing in a separate dedicated smoker later on.

Pizza Stone for Monarch & Royal

Best for: Monarch and Royal owners baking artisan flatbreads

Pros

• Reversible dual-sided stone surface
• Even heat retention and spread
• Tailored fit for Monarch and Royal

Cons

• Grill accessory only, not freestanding
• Listing omits exact dimensions

Expanding the versatility of smaller and mid-sized gas grills, the Pizza Stone for Monarch & Royal transforms standard fireboxes into thermal convection ovens. Engineered to fit directly within the cooking chambers of Broil King Monarch and Royal series grills, this cooking accessory allows backyard chefs to bake thin-crust pizzas, artisan flatbreads, and rustic loaves directly over open gas burners without heating an indoor kitchen.

The stone features a reversible two-sided construction in a neutral gray finish, designed for even heat distribution across its entire surface. By absorbing direct conductive heat from the burners below, the stone draws moisture out of raw dough to produce a crispy crust while allowing toppings to bake uniformly. The reversible surface allows either side to be used, simplifying cleaning as food residue chars away under high temperatures. The listing does not specify exact physical measurements or overall weight, but confirms exact compatibility with Monarch and Royal grill geometries.

This stone is intended for existing or prospective Royal owners who want to explore outdoor baking. While not a freestanding grill, it serves as an economical expansion tool that broadens the culinary scope of three-burner gas cookboxes.

Pellet Grill by Broil King

Best for: Barbecue pitmasters prioritizing app-controlled wood smoking

Pros

• WiFi and Bluetooth app controller
• Motorized spit rotisserie included
• Heavy 14-gauge steel body

Cons

• Substantial 225-pound total weight
• Requires access to electric power

The Pellet Grill by Broil King, identified in its description as the Regal Pellet 400, is a dedicated wood-fired cooker built from heavy-duty 2mm (14-gauge) steel. The grill offers 630 square inches of total cooking capacity, split into 500 square inches of primary space and 130 square inches of secondary space over heavy-duty cast iron cooking grids. Its side-mounted steel fuel hopper holds up to 22 pounds of hardwood pellets, providing steady fuel flow for extended low-and-slow smoking sessions. A motorized stainless steel rotisserie kit with spit rod and forks is included directly in the box.

Precision temperature management on this broil king pellet grill is handled by a digital controller with a dial interface and push-button temperature presets for smoking, roasting, or high-heat searing. The finish uses high-heat paint rated to withstand temperatures up to 600 degrees Celsius (1000 degrees Fahrenheit). Integrated WiFi and Bluetooth connect the grill to the Broil King App, allowing monitoring via two included electronic meat probes from a smartphone. While portable alternatives like a portable blackstone grill for camping are built for travel, this 225-pound stationary unit remains firmly planted on the patio with lower base storage, a side prep shelf, and integrated grease and ash management systems.

Referred to in its listing overview as the Broil King Regal Pellet 400, this cooking system caters to barbecue purists who demand genuine wood smoke aroma, hands-off digital consistency, and motorized rotisserie roasting in a permanent backyard fixture.

Matching a Model to Your Setup

• For tight condo balconies and compact patios: The Broil King 814954 Gem 310 Shadow fits into restricted spaces with folding resin side shelves and a slim pedestal footprint while supplying 24,000 BTUs across three burners.
• For suburban yards requiring enclosed storage: The Broil King 824154 Royal 320 Shadow provides 500 square inches of total space and 30,000 BTUs within an enclosed cabinet that conceals the propane cylinder.
• For large family cookouts and complete meal prep: The Broil King 865364 Crown S 440 offers four primary burners, 630 square inches of cooking area, and a 10,000 BTU side burner for sauces.
• For high-capacity entertaining and hybrid smoking: The Broil King 675144 Baron 590 Pro delivers five burners, 780 square inches of surface, illuminated control knobs, and compatibility with the optional iQue pellet fuel module.
• For slow-smoked barbecue enthusiasts: The Pellet Grill by Broil King provides smartphone app monitoring, a 22-pound hopper, and an included motorized rotisserie for authentic wood-fired roasting.
• For artisan pizza baking on an existing grill: The Pizza Stone for Monarch & Royal equips Royal owners with a reversible stone surface that bakes crusty flatbreads directly over gas heat.

Before You Buy

Before purchasing your cooking equipment, confirm which accessories and fuel components are required to make the unit fully operational. Standard liquid propane tanks are not supplied with the Crown, Gem, Royal, or Baron gas grills and must be purchased separately. While the Baron 590 Pro is marketed as pellet-ready, the modular iQue Pellet Fuel Kit (SKU 675001) is not included in the carton and must be acquired to enable wood-pellet operation. Protective outdoor covers—such as model 67487 for the Crown or models 67470 and 67468 for the Gem and Royal—are also separate purchases.

Review the physical specifications and utility needs for each model carefully. The listing for the Baron 590 Pro states dimensions of 4 inches deep by 4.1 inches wide by 18.5 inches high, which clearly represents component packaging rather than the assembled five-burner footprint; plan your patio clearance according to standard multi-burner cabinet dimensions. In addition, the listing for the Pizza Stone for Monarch & Royal does not specify exact dimensions or overall weight, confirming only direct fitment for those two lines. If you choose the Pellet Grill, ensure you have an accessible outdoor electrical outlet nearby, as its automated auger, digital controller, and motorized spit rod require constant utility power.

FAQ

How does the Broil King Flav-R-Wave system work?

The Flav-R-Wave system consists of full-coverage stainless steel shields positioned above the burners. When drippings and marinades fall during grilling, they strike the hot stainless steel plates and vaporize instantly. This process turns meat juices into aromatic smoke that infuses food with barbecue flavor while preventing excess grease from hitting open flames and causing flare-ups.

What is the benefit of Broil King Dual-Tube burners?

Dual-Tube burners feature an internal tube within the main burner pipe that balances gas pressure from the front of the cookbox to the rear. In traditional single-tube designs, gas pressure can decrease toward the back, leading to uneven cooking temperatures. The Dual-Tube architecture equalizes fuel distribution to ensure uniform flame height and consistent heat across the entire grate surface.

Can the Baron 590 Pro use wood pellets right out of the box?

No, the Baron 590 Pro arrives configured strictly as a propane gas grill equipped with five Dual-Tube burners, a side burner, and a rear rotisserie burner. To burn wood pellets, you must purchase the iQue Pellet Fuel Kit (SKU 675001), which mounts to the grill chassis to provide hybrid wood-fired functionality.

How do you use the reversible cooking grids on Broil King grills?

The reversible grids offer two distinct cooking orientations. The pointed side concentrates heat to brand steakhouse sear marks onto steaks, chops, and burgers. Inverting the grates reveals continuous channels that catch drippings to baste delicate fish, chicken, and vegetables in their own juices while channeling excess fat toward the grease collector.

Which Broil King grill is easiest to store in small spaces?

The Broil King 814954 Gem 310 Shadow is the most compact freestanding grill in the lineup. Its pedestal base occupies minimal patio floor space, and both resin side shelves fold down flat to reduce width, allowing the grill to tuck away cleanly into balcony or patio corners when not in use.