One of Consumer Reports' standard tests for medium-sized grills, six steaks are cooked on the hot grill to see how much flare up there is.

Like several grills there was quite a bit with the $650 Broil King Signet 90. But there was a much more serious problem, the bottom of the grill's firebox began melting.

"We've been testing gas grills for 30-years and this is the first time we've ever seen anything like this." said Consumer Reports' Mark Connelly.

All three Broil King Signet 90s Consumer Reports tested had problems.

"Molten metal actually dripped down under the grill. It just missed the hand of one of our testers." said Connelly

Consumer Reports has judged the Broil King Signet 90 "Not Acceptable," and has notified the manufacturer, as well as government safety agencies.

The company says it has developed a free retrofit kit that's supposed to resolve the problem. Consumer Reports plans on testing it. For those who own one of these grills, additional information is available on the company's Web site.

All the other grills Consumer Reports tested rated good to excellent.

Top Rated:
Weber Genesis E320 for $700, midsized, heats evenly and proved excellent at grilling

Best Buys:
Brinkmann 8108410S, for $200 from Home Depot
Char-Broil Commercial Series 463268008, for $300 from Lowe's