The most expensive measurement in an outdoor kitchen can be the one nobody wrote down. A built-in grill’s advertised width is not its cutout width. The opening must support the appliance exactly as the manufacturer specifies.
This guide explains how a built-in grill seats in an island, what width, height and depth mean on a cutout sheet, and how current KoKoMo built-in dimensions compare before fabrication begins.
How a built-in grill actually sits in the opening
A built-in grill head is supported by the countertop or enclosure around the cutout. The opening therefore needs to match the manufacturer’s specified dimensions rather than the appliance’s overall outside dimensions.
- Use the manufacturer cutout dimensions. Overall product width is not a substitute for the installation opening.
- Plan support and clearances together. The island must support the appliance while preserving the required space around combustible materials.
- Verify the physical unit before the final cut. Model revisions and documentation can change, while finished stone is difficult to correct.
What the three measurements mean
Width is the horizontal opening across the island. Height is the vertical drop below the countertop. Depth is the front-to-back opening. All three matter for a flush, supported installation.
KoKoMo built-in grill cutout dimensions
These figures reflect current manufacturer product information checked for this guide. Always compare them with the current documentation for the exact SKU you receive.
| Model | Cutout Width | Cutout Height | Cutout Depth | Overall / Planning Note |
|---|---|---|---|---|
| 26″ Classic 3-Burner Gas KO-BAK3BG |
23½″ | 8⅝″ | 21¼″ | 25″ × 18½″ × 24⅜″ |
| 32″ Professional 4-Burner Gas KO-PRO-4BG |
30⅞″ | 8⅝″ | 21¼″ | 32½″ × 18½″ × 24⅜″ |
| 40″ Classic 5-Burner Gas KO-BAK5BG |
38″ | 8⅝″ | 21¼″ | Check current model sheet for final outside dimensions. |
| 40″ Professional 5-Burner Gas KO-PRO-5BG |
38″ | 8⅝″ | 21¼″ | 39¾″ × 18½″ × 24⅜″ |
| 32″ Classic Built-In Charcoal KO-CHAR32 |
30¾″ | 17¾″ | 12½″ | Manufacturer currently lists 32.5 × 24 × 24.5 in overall; confirm orientation on the current model sheet. |
| 30″ Professional Gas Griddle KO-GRDL30-PRO |
Confirm current sheet | — | — | Manufacturer product information should be checked before fabrication. |
Current product pages and older installation documents can also differ slightly for certain models. When there is any conflict, use the current documentation for the exact model and revision being installed, then confirm the received appliance before final fabrication.
Cutout dimensions are only part of the installation
A correct opening still needs the right enclosure, clearances and utility planning.
Non-combustible construction
KoKoMo’s installation guidance calls for a non-combustible BBQ island. Follow the current model instructions and local code for the enclosure being built.
Combustible clearances
Current KoKoMo documentation includes 14-inch side and 16-inch rear guidance near combustible construction, while another section states at least 18 inches from combustible material. Use the more restrictive requirement that applies to the exact model and local installation.
Gas access and shutoff
Plan the gas connection and shutoff so they remain serviceable after the grill is installed. Fuel work should be completed by a qualified professional and follow applicable code.
Electrical requirements
Models with powered lighting or controls may require an outdoor-rated grounded electrical supply. Confirm this before the island is closed.
Not every built-in grill uses the same geometry
Built-in Argentine grills such as the Tagwood BBQ28SS use a different appliance format from a conventional gas grill head. That is another reason to choose the exact appliance before the island is designed.
For a broader look at the models currently available, browse our Built-In Grills for Outdoor Kitchens collection.
A fabrication sequence that reduces rework
Choose the exact appliance
Size, fuel type and installation format become inputs to the island design.
Obtain the current installation documents
Use the manufacturer documentation for the exact model and revision, not a generic category measurement.
Design around cutout and clearances
Coordinate width, depth, enclosure material, combustible clearances and usable counter space.
Plan gas and power
Utility routing is much easier before finished surfaces are installed.
Verify the received appliance
Check the actual model and dimensions against the current sheet before final fabrication.
Make the final cut
Give the fabricator the verified cutout dimensions and applicable installation requirements.
Common built-in grill cutout mistakes
Using the advertised grill width as the opening width
The outside appliance dimension and manufacturer cutout dimension serve different purposes. Always use the published cutout specification.
Checking width but ignoring height and depth
A grill can match the opening width and still fail to seat properly if the enclosure is too shallow or the vertical opening is wrong.
Using an old spec sheet without checking the model revision
Installation information can change. Match the document to the exact SKU and appliance being installed.
Building the island before choosing the grill
This reverses the process and can limit you to whatever happens to fit the opening after the fact.
Forgetting access to utilities
Gas shutoffs, connections and electrical components should remain accessible for inspection and service.
Assuming one person can safely place a large grill head
Large built-in units can be heavy. Plan appropriate lifting assistance based on the current product weight and installation instructions.
Built-in grill cutout questions
What if my existing cutout is slightly too large?
Do not assume the appliance flange provides enough support. Have the fabricator or installer evaluate the remaining bearing surface against the current installation requirements before placing the grill.
What if the cutout is too small?
A qualified fabricator may be able to enlarge the opening, but the final dimensions still need to match the manufacturer specification and enclosure requirements.
Can I replace an old built-in grill using the same opening?
Sometimes. Measure the existing opening in all three dimensions and compare it with the current cutout requirements for the replacement models you are considering.
Do built-in grills always need an insulated jacket?
No single rule applies to every appliance and enclosure. Check the exact model’s installation instructions, enclosure material, ventilation requirements and combustible clearances.
Can I get help checking a cutout before ordering?
Yes. Send the opening width, height and depth, enclosure material, fuel type and model you are considering through our project support page, or call 833-777-2962.
Choose the grill before your fabricator commits to the opening
We can help you compare current product dimensions and point you to the manufacturer documentation for the model you are considering. Final fabrication and installation should be confirmed against the exact appliance and applicable local requirements.
Related: How to Plan an Outdoor Kitchen · Built-In vs. Freestanding Grill · KoKoMo Grills
