Every grill project comes down to one hole in a countertop. Get it right and the built-in grill drops in and sits flush. Get it wrong by half an inch and you are calling a mason, a stone fabricator or both. We field this question constantly from two kinds of people: those about to build an island who want to avoid a mistake, and those with an island already built who want to know what will fit in it.
This guide covers both. It explains what the numbers on a cutout sheet mean, how to measure an existing opening, what clearances and insulated jackets change, and what to do when the opening is too big or too small. If you are still choosing a size, start with what size grill do I need and 36 vs. 42 inch built-in grills, then come back here to plan the opening.
The short answer
Never size the opening from the grill head. Every manufacturer publishes a cutout width, depth and height for each model, and those numbers are smaller than the head because the head hangs from the countertop around the opening. For an existing island, measure the width at the front and back, the depth from the finished front face, and the height from the top of the counter to the ledge or deck below, then compare them to the installation manual for the exact grill. If the frame is wood or anything else combustible, the grill needs the brand's insulated jacket, and the jacket needs a larger opening than the grill alone.
Key takeaways
- The cutout is smaller than the grill head. A Fire Magic Echelon E790i head is 40 1/4 inches wide and needs a 37 inch opening.
- Cutout width, depth and height are three separate numbers, and there is a fourth (control panel width) that matters when the countertop overhangs the front of the island.
- There is no standard 36 inch cutout. The 36 class grills we carry run from 34 1/4 to 37 inches wide and from 19 1/2 to 24 1/4 inches deep.
- A combustible island (wood framing, even under stucco or tile) requires the manufacturer's insulated jacket, and the jacketed opening is several inches wider and deeper than the plain one.
- For an existing island, measure at the front and back, use the smaller number, and note where the gas stub and outlet are before you pick a grill.
- Too big can usually be fixed with a trim kit or filler frame. Too small usually means reworking the island, and width is the hardest direction.
In this guide
- The four numbers at a glance
- What is the difference between grill head size and cutout size?
- What are control panel width and countertop overhang?
- How much clearance does a built-in grill need?
- Do you need an insulated jacket?
- How do you measure an existing island opening?
- Where do the gas line and power need to be?
- What if the opening is too big?
- What if the opening is too small?
- Which grill fits the opening you already have?
- Our recommended models
- Which should you choose?
- Frequently asked questions
The four numbers at a glance
Here is how to read a cutout sheet, using the Fire Magic Echelon E790i as the worked example. Fire Magic publishes every figure below in its specification guide and installation manual.
| Number | What it is | E790i example | Common mistake |
|---|---|---|---|
| Grill head overall | The full size of the finished grill, including the flanges that rest on the counter | 40 1/4 in W x 30 1/2 in D | Framing the opening to this number |
| Cutout width | Side to side opening the grill body drops through | 37 in | Measuring at the front only |
| Cutout depth | Front to back, including any front wall substrate | 23 1/2 in | Forgetting the veneer or backer board |
| Cutout height | Top of the countertop down to the underside of the grill body | 11 1/2 in | Leaving out the countertop thickness |
| Control panel width | The width of the front panel, which can be wider than the cutout | 38 3/4 in | Ignoring it when the counter overhangs |
What is the difference between grill head size and cutout size?
The grill head is the finished appliance you see: hood, control panel, side flanges. The cutout is the opening in the counter and island that the body of the grill sinks into. The head is always bigger, because the flanges and control panel rest on the countertop around the opening. On the Echelon E790i the head is 3 1/4 inches wider than the cutout. On the Lynx 36 it is only 1 inch wider. That overlap is all the head has to hide a rough or oversized edge.
The name on the box tells you almost nothing. Brands name grills by cooking width or by marketing size, and the opening does not follow. Here are four grills in the 34 to 36 inch class that we install, with the listed grill size next to the manufacturer cutout. Listed sizes come from the product specifications and cutouts from the manufacturer sheets.
| Grill | Listed grill size (W x D) | Cutout (W x D x H) |
|---|---|---|
| Fire Magic Echelon E790i | 40 1/4 x 30 1/2 in | 37 x 23 1/2 x 11 1/2 in |
| Lynx Professional L36TR | 36 x 25 3/8 in | 35 x 22 x 10 1/8 in |
| Twin Eagles 36 | 36 x about 29 5/8 in | 34 1/4 x 24 1/4 x 11 3/4 in |
| Blaze Professional LUX 34 | 34 x 28 3/8 in | 32 1/4 x 23 5/8 x 10 1/2 in |
Almost five inches of width separate the widest and narrowest of those, and the depth range is more than two inches. That is why we say pick the grill before anyone cuts anything. The built-in vs. freestanding guide makes the same point from the other direction: a head you plan to build in later needs a real cutout sheet, so keep it.
What are control panel width and countertop overhang?
This is the detail that trips up good installers. On many grills the control panel is wider than the cutout. The Echelon E790i panel is 38 3/4 inches wide against a 37 inch opening. The panel has to sit flush against the front wall of the island, with the side fire walls of the grill behind it covered.
If your countertop overhangs the front of the island, as most do, the stone has to be notched to the panel width at the front or the overhang will push the grill back and leave a visible gap. Fire Magic gives the formula in its manual: overhang per side equals the control panel width minus the cutout width, divided by two. For the E790i that works out to 7/8 inch per side. Lynx makes a similar point and asks for a countertop notch detail only where the counter overhangs the island face. It also asks that the ledges and the countertop be flat and level.
From our install team
Ask your stone fabricator for the notch drawing before the slab is cut, not after. A notch is easy to cut with the slab on the saw table and very hard to add once it is set. If the countertop is already installed with a full overhang, measure it before you shortlist grills.
How much clearance does a built-in grill need?
Clearance is the distance from the grill to anything that can burn. Each manufacturer tests its own grills and publishes its own minimums, so two grills in the same island can have different numbers. What we can give you is a snapshot of what four brands publish. It is not a substitute for your model's manual.
| Brand | Combustible construction | Noncombustible walls and notes |
|---|---|---|
| Fire Magic Echelon | 18 in to a combustible rear wall; 14 in to a protected combustible wall | 4 in to a noncombustible rear wall; 24 in to side walls and corner walls; 6 in beside the control panel; 5 ft from the countertop to overhead construction |
| Twin Eagles 36, 42, 54 | 12 in at the sides and back, 18 in where combustible construction rises above the countertop | 4 1/2 in behind the grill above the cooking surface so the hood opens; below the cooking surface the grill can sit against noncombustible construction |
| Lynx Professional | 12 in at the sides and 6 1/4 in at the back of the hood | 3 in behind for the front hood to open; 6 in on the left above the counter for the rotisserie motor |
| Hestan | 12 in from vertical combustible material at the sides and rear | Jacket required for combustible islands |
Overhead is the stricter rule. Fire Magic and Lynx both say not to install under unprotected combustible overhead construction, and both specify an exhaust hood of at least 1,200 CFM where there is overhead cover. Twin Eagles specifies a ventilating hood wider than the grill and at least 36 inches above the cooking surface. Our vent hood guide covers when a covered patio needs one.
In New York City, natural gas grills must be installed by a licensed master plumber under the NYC Fuel Gas Code, and the piping is inspected and tested. The Department of Buildings barbecue guidance also says to keep a grill 10 feet from anything that can easily catch fire, which a permanent island on a small terrace can run into. For a built-in on a co-op roof or terrace, ask your building and your board how it applies before you design the island.
Do you need an insulated jacket?
An insulated jacket (Fire Magic and Summerset call theirs a liner) is a stainless sleeve with insulation that goes around the grill body inside the island. It is what makes it safe to put a built-in grill into a combustible enclosure. The rule from the manufacturers is consistent: Lynx says installation into a combustible enclosure requires its insulated jacket accessory; Fire Magic says an approved insulating liner is required; Twin Eagles says its insulating jacket is required; and Hestan says the same for its AGIJ jackets.
What counts as combustible? Wood framing, obviously. But Hestan's instructions add something people miss: wood beneath a noncombustible surface such as stucco or tile still counts as combustible. A stucco island with a pressure-treated frame behind it needs the jacket. A block, brick, stone or poured concrete island, or a metal stud frame covered with noncombustible board, does not. Rooftop and deck islands are usually built light, in wood or steel frame, so the jacket question comes up often there. A masonry island on a Long Island patio is noncombustible and usually does not need one.
Why it matters for measuring: the jacketed opening is bigger than the plain one. Lynx lists the Professional 36 at 35 inches wide, 22 inches deep and about 10 1/8 inches high. With the Lynx 36 inch jacket the opening grows to 42 inches wide, 24 inches deep and about 11 5/8 inches high. Blaze lists the Professional LUX 34 at 32 1/4 x 23 5/8 x 10 1/2 inches, and its jacket needs 34 7/8 x 24 1/2 x 11 inches. Fire Magic notes that cutout dimensions change when a liner is used. Plan the opening for the jacket from the start, because you cannot add one later without rebuilding.
From our install team
The island has to support the jacket, not the other way around. Lynx wants it carried on a ledge on each side or a full deck. If an island was framed in wood for a bare grill, the jacket will not fit the opening. If you are not sure how an island was built, open the access door and look before you order.
Find the jacket for your grill in insulated jackets and trim kits. Jackets are brand and size specific, so match the model number exactly. Examples we stock include the Twin Eagles 36 jacket, the Fire Magic E790i and A790i liner, the Blaze Professional LUX 3-burner jacket and the Hestan 36 jacket.
Shop insulated jackets and trim kits Shop built-in grills
How do you measure an existing island opening?
Do this with a tape, a level, a framing square, your phone for photos and the model number of the grill you are considering. Measure the finished opening, with countertop, veneer and any backer board in place.
- Width, at three places. Measure side to side at the front edge of the counter, at the back of the opening and down at the ledge level. Write all three down. If they differ, the smallest one is your real width.
- Depth, from the finished front face. Measure from the front of the island, including stone or tile veneer, to the back wall of the opening. The manufacturer's depth figure includes any front wall substrate, so include it too.
- Height, from the top of the counter. Measure from the top of the finished countertop straight down to the ledge, deck or floor below the opening. That is the room the grill body has to hang in. Fire Magic defines cutout height as the distance from the countertop down to the bottom of the unit, and cutout heights generally include a small air gap beneath the grill, so check how your brand defines it.
- Corners and squareness. Check that the opening is square by measuring both diagonals. Stone fabricators often round the inside corners of a cutout to keep the slab from cracking, so make sure the grill's square corners clear them.
- Countertop thickness and overhang. Note the thickness and how far the counter overhangs the front face, because the control panel width comes into play.
- Framing. Open the access door. Is the frame wood, metal stud or masonry? That decides whether you need a jacket.
- Clearances. Measure from the opening to the nearest wall, side counter and appliance, and look up the grill's published clearances.
- Gas and electrical. Note where the gas stub, shutoff valve and outlet are (see the next section).
- Old grill. If there is a grill in the island now, take a photo of the model plate. The model number gets you its cutout sheet and tells you what the island was built for.
From our install team
When we are asked to retrofit a grill into someone else's island, the first thing we look for is the old grill's model plate. If the opening matches a published cutout sheet to within a quarter inch, the island was built right and the job is simple. If the opening matches nothing, it was probably framed to the hood width, and we plan for the fix before we quote the grill.
Not sure what fits your space? Send us the three width measurements, the depth, the height and a photo of the inside of the island, and we will tell you which grills match before you buy one. Book a free design consultation and we will help you narrow it down.
Where do the gas line and power need to be?
The gas stub and outlet decide whether a replacement drops in or turns into a plumbing job. The manufacturers say:
- Fire Magic Echelon: if a solid deck is under the grill, cut a 1 1/2 inch hole for the gas line and another for the lower power connection. The shutoff valve (not included) must be within 6 feet and easy to reach. The unit needs a 120 volt GFCI receptacle with a weatherproof in-use cover, and its power supply mounts at least 12 inches below the unit.
- Lynx Professional: gas exits at the rear, with a 1/2 inch male fitting. The manual shows where the manifold falls for each model and says to keep the flex line from running behind the firebox. The rear panel cutout includes a 1 inch square hole for the power cord, with a 120 volt GFI outlet within 6 inches of it.
- Twin Eagles: gas can come in at the rear or bottom. Keep the supply line as short as you can, away from hot surfaces, with an accessible shutoff.
The old grill's stub is rarely in the right place for a new model. Expect to move the stub and the outlet when you change brands or sizes, and that is plumbing and electrical work, not a swap. In New York City that means a licensed master plumber and, for gas, inspection and testing of the piping.
What if the opening is too big?
An oversized opening is the easier problem. The grill head hides a small margin around the opening, and anything beyond that shows. Your options, in the order we usually try them:
- Check the head overlap first. Compare the head size to your opening, not just the cutout sheet. If the opening is only slightly over the cutout and the head still covers it, you may be done. The Echelon E790i head is 3 1/4 inches wider than its cutout; the Lynx 36 is only 1 inch wider.
- Manufacturer trim kit. Some brands sell stainless trim kits or surrounds made to close a specific opening, usually for an older series. If the brand of the new grill sells one for your model, it is the cleanest fix. Not every model has one.
- Stainless filler frame. A metal fabricator can build a flat frame that sits on the ledges and shrinks the visible opening. It has to be noncombustible and cannot block the airflow gap beneath the grill or the hood clearance behind it.
- Narrow the opening. Add framing and veneer on one or both sides and trim the stone. This is the most work but gives the cleanest result.
- Choose a wider grill. Often it is cheaper to move up one size than to repair an opening that is a few inches wide. Check the cutout, not the name.
Whatever you choose, do not leave an open gap around the grill. It lets heat and grease reach the frame and it is exactly what the clearance rules are written to prevent.
What if the opening is too small?
Depth and height are the easier directions. If the opening is too shallow, the rear wall or a back panel can often be cut back. If it is not tall enough, the ledge or deck can often be lowered. Width is the hard one, because the countertop on both sides is in the way.
Widening a stone countertop opening is risky. A set slab can crack when it is cut, and a patch rarely matches the grain, edge profile and color. Fabricators often prefer to make a new section rather than enlarge an old cut. Tile or poured concrete is more forgiving, but it is still masonry work.
Before you reopen the island, check whether another grill has a smaller cutout. The table in the next section helps, because a grill with a bigger name can need a smaller hole. Keep the jacket in mind: if the island is combustible, the jacketed opening is the one that has to fit.
Which grill fits the opening you already have?
This is a quick lookup of cutout sizes for popular built-in grills, from narrowest to widest. These are bare-grill cutouts without a jacket. Use them to find candidates, then confirm in the manual.
| Grill | Cutout width | Cutout depth | Cutout height |
|---|---|---|---|
| Blaze BCM 25 | 23 1/4 in | 21 1/4 in | 8 1/2 in |
| Fire Magic Aurora A430i | 25 1/2 in | 19 1/2 in | 11 1/2 in |
| Lynx Professional 30 | 29 in | 24 1/2 in | 10 7/8 in |
| Blaze Premium LTE+ 32 | 30 5/8 in | 21 1/4 in | 8 1/2 in |
| Fire Magic Aurora A540i | 32 in | 19 1/2 in | 11 1/2 in |
| Blaze Professional LUX 34 | 32 1/4 in | 23 5/8 in | 10 1/2 in |
| Summerset Quest 36 | 34 1/4 in | 19 1/2 in | 9 7/8 in |
| Twin Eagles 36 | 34 1/4 in | 24 1/4 in | 11 3/4 in |
| Hestan 36 | 35 in | 23 1/2 in | 12 in |
| Lynx Professional 36 | 35 in | 22 in | 10 1/8 in |
| Fire Magic Echelon E790i | 37 in | 23 1/2 in | 11 1/2 in |
Notice the Blaze LTE+ 32: it needs 30 5/8 inches, which is a hair too wide for a true 30 inch opening. A 30 inch opening takes the Lynx Professional 30 or the Fire Magic A430i, but not the LTE+ 32. Depth is where the lineups split. The Fire Magic Aurora A540i and the Summerset Quest 36 need 19 1/2 inches, while the Twin Eagles 36 needs 24 1/4, which can save an island that is short on depth. Browse by class: 26 inches and under, 27 to 32, 34 to 42 or over 42.
From our install team
Do not trust a cutout number from a retailer listing, a forum or this table without checking it against the installation manual for the exact model. Brands revise cutouts between series, and listings sometimes disagree with the sheet. We confirm every cutout against the manufacturer's sheet before we quote an install.
Our recommended models
These are grills and jackets we plan around when a customer has a specific opening in mind. We picked them for clear published cutout sheets and for jackets that are available for the same model.
Grill heads
Jackets and liners
Insulated jackets and trim kits Built-in grills Outdoor kitchen islands Access doors and drawers
Which should you choose?
Match a grill to the opening you have if:
- The island is masonry or metal stud and in good shape.
- The opening matches a published cutout sheet within a quarter inch.
- The gas stub and outlet are already near the right spot.
- Your priority is to keep the countertop you have.
Rebuild or modify the opening if:
- The frame is wood and a jacket will not fit the current opening.
- The opening is several inches too big or too narrow for the grill you want.
- The countertop overhang blocks the control panel.
- The gas and power need to move anyway.
Our recommendation: pick the grill from the opening, not the opening from the grill, as long as the island is sound. Use the lookup table above to find the grills that fit, confirm against the manual, and only reopen the island if nothing you like fits. If the island is wood framed, price the jacket and the larger opening in from day one. And if you are building new, choose the grill before the frame goes up, then build to its cutout sheet.
Frequently asked questions
How do I measure the cutout for a built-in grill?
Do not measure the grill head. Look up the cutout width, depth and height for your exact model in the manufacturer's installation manual or cutout sheet, then frame the opening to those numbers. For an existing island, measure the opening's width at the front and back, its depth from the finished front face, and the height from the top of the countertop to the ledge or deck below, then compare all three to the sheet.
What is the standard cutout size for a 36 inch built-in grill?
There is no standard. Among the 36 class grills we sell, cutout widths run from 34 1/4 inches (Twin Eagles and Summerset Quest) to 35 inches (Lynx Professional and Hestan) to 37 inches (Fire Magic Echelon E790i), and depths run from 19 1/2 to 24 1/4 inches. Use the sheet for the exact model.
Can I replace my built-in grill with a different brand?
Sometimes. The new grill's cutout has to fit the existing opening in width, depth and height, and the island has to meet the new brand's clearances. If the opening is a little too big, a manufacturer trim kit or a stainless filler frame can close the gap. If it is too small, the island has to be opened up, which is easiest in depth and height and hardest in width.
What grill fits a 30 inch cutout?
Any grill whose published cutout width is 30 inches or less, if depth and height also fit. Examples are the Lynx Professional 30 (29 inch cutout) and the Fire Magic Aurora A430i (25 1/2 inch cutout). The Blaze Premium LTE+ 32 needs 30 5/8 inches, so it will not drop into a true 30 inch opening.
How much clearance does a built-in grill need from combustibles?
It depends on the brand. Twin Eagles lists 12 inches from vertical combustible construction at the sides and back. Lynx lists 12 inches at the sides and 6 1/4 inches at the back of the hood. Fire Magic's Echelon manual calls for 4 inches to a noncombustible rear wall, 14 inches to a protected combustible wall and 18 inches to a combustible one. Follow the manual for your model.
Do I need an insulated jacket for a built-in grill?
You need one if the island frame or any material around the grill is combustible, such as wood framing. Lynx, Fire Magic, Twin Eagles and Hestan all require their own jacket or liner for combustible enclosures. A stone, block, brick or metal stud island that is noncombustible does not need one.
How deep does an island need to be for a built-in grill?
Deeper than the cutout depth. Cutout depths in the grills we sell run from 19 1/2 to 24 1/4 inches, and you still have the thickness of the front and back walls plus rear space for the hood to open, which is 3 to 4 1/2 inches in the Lynx and Twin Eagles manuals. A jacket adds more.
What if my cutout is too big for the new grill?
Check how much of the gap the grill head covers. If it is small, a manufacturer trim kit or a custom stainless filler frame can close it. If it is large, the cleaner fix is to narrow the opening with new framing and re-set or replace the countertop section. Never leave an open gap around the grill.
Talk to a specialist
Send us your cutout measurements and we will tell you what fits.
We have been designing, selling, installing and servicing fire features and outdoor kitchens for over 30 years across New York City, Long Island, Westchester, New Jersey and South Florida. Bring us the measurements, a photo of the inside of the island and the old grill's model number, and we will match the grill, the jacket and the gas line.
Book a free consultation Call 718-326-4328Showroom: 58-30 Maspeth Ave, Maspeth, Queens.
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Written by the NYC Fireplaces & Outdoor Kitchens team. Last reviewed October 2026. We sell, install and service the products discussed here.
Sources: Fire Magic Product Specifications Guide, Fire Magic insulating liner, Lynx Professional built-in grills and installation manual, Twin Eagles grills and installation manual, Blaze Professional LUX 34, Hestan Outdoor insulated jacket instructions, NYC Department of Buildings barbecue guidance. Specifications change; always confirm with the manufacturer's current installation manual.