Kettle leaking smoke

[7x57mm]

Just how much is too much? I purchased my 22.5" Performer in 2013. From day one, it leaks smoke in about a 4" section. Binder clips don't correct the issue. Since most of my cooks involve searing and roasting, I never paid much attention or had much concern. Now, enter the SNS in 2015. With the SNS, I can keep temps 240-255 with the bottom vent cracked to the width of a wire coat hanger but I have never been able to hit and keep 225. I turned a couple of pards onto the SNS this year and they can keep 200-225 on their Weber kettles. I measured my kettle lid and there is a 1/16" or so difference where the smoke leaks out when compared to other measurements on the lid. The bowl is spot on with every measurement. At the end of the cook, I can snuff out coals without a problem when the vents are closed. I use a Mav 732 thermometer and it is spot on when tested in boiling water. Long story short, am I making too much out of nothing?

Tangent: my 3 year old Weber cover is dead...tater chip dry I'd just soon not use a cover but it rains a lot here in the Portland Oregon metro area during winter and spring. To cover or not to cover....that is the question.

[JeffJ]

Cover. Definitely. Mine last about 3 years here in Michigan. I wouldn't worry about leaking smoke and I certainly wouldn't worry about hitting 225. It's the most over rated temperature. With the exception of baby backs I target the 235-280 range.

[Thunder77]

If you are having a difficult time with temp control, then I would get a gasket for the lid. If you are able to control temps even with the leakage, then don't worry about it. Mine kind of leaked a lot, so I wasn't able to consistently control temps, and I installed a nomex gasket.

I agree with JeffJ about the temperature. 225 is only a target temp. I regularly cook ribs and butts at anywhere from 225-240.

Be aware that if you do install a gasket, you will probably have to re-do your vent settings, due to less leakage. I certainly did!
Oh, and I definitely cover my grill.

[MBMorgan]

Check out the grill covers from these folks: https://www.amazon.com/AmazonBasics-...5_5_2515622962

I got one for my Genesis a year ago. Infinitely better than those plastic covers you get from grill manufacturers ... less expensive, too. Still like new in spite of excessive exposure to Colorado sun and snow.

[Potkettleblack]

Which size did you get for the Genesis?

[MBMorgan]

Potkettleblack - This one: https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

[7x57mm]

Thanks for the info everyone. I don't have a problem with chasing temps (unless it is my fault!). My cooker just runs hot. And, thanks for the cover link Mbmorgan. I'll be ordering a replacement this week.

[7x57mm]

Follow-up on the Performer grill cover I purchased earlier and received today.... https://www.amazon.com/gp/product/B0...ag=amazi0a8-20

Folks, this grill cover is night and day superior to the Weber cover and it's cheaper to boot. Although made in China (grrrr), the quality is simply superb. Of course, it rained like crazy yesterday and for the next 5+ days, it will be sunny and 80+ degrees My biggest hope is that the vents sewn into the cover will prevent condensation build up. Time will tell if this cover becomes hard and brittle. Me thinks it will not.

[Histrix]

I have about a half dozen Ravenna covers for various grills/things on my patio. They are well made at a fair price. Far superior to any of the Weber covers.

None of mine are getting brittle or hard (they can be a bit stiff in the winter) but they will fade.

[bbqstud]

Not being sarcastic but who cares if it leaks a little? And 10 degrees in temp is no big deal...not even in competition...relax and enjoy the time, Q and your favorite beverage....

[7x57mm]

Thanks for the feedback Histrix; the construction/material quality of the Ravenna is excellent! Bbqstud....no sarcasim taken. I can't run my kettle at 225 and from what I've read over the past couple of years, it's due to my "leaky" kettle lid. If I try to run my cook with the suggested SnS vent settings, my temps will be 280-300 degrees. I forget which BBQ forum I read this on but the suggestion was to use a wire coat hanger as a gauge to set the bottom vent opening. Once I tried that, a sub 260 temp is guaranteed...just not the magical 225

[7x57mm]

Ribs….my nemesis. I’ve only smoked a dozen or less racks in the past couple of years simply because they have not turned out how I would like….not bad mind you (flavor and texture), but not the toe curling "Last Meal Ribs" I want. Temp is my Achilles heel (I think) with ribs. It was a perfect day for smoking…70 degrees and no wind. My kettle runs hot with 260 being the norm. I’ve smoked a lot of butts at that temp without issue…always a winner. I decided to try starting my SnS fire today using a Weber starter cube instead of my usual weber chimney method. It took 32 minutes to get 12 coals ashed over. Cubes will be benched and used only if and when I have no newspaper or matches to start the chimney I decided to put the ribs on the grill once the temp hit 150 degrees and set my upper vent to 1/3 and the intake to just a crack. Temps slowly climbed and held at 243 for the next 2 hours which is typical with my leaky kettle (binder clips don’t stop the leaking). Thirty minutes later, the temp rose to 253 and 30 minutes after that, the temp hit 259. I didn’t lift the lid for 3 hours but I decided to put cold water in the water trough to act as a heat sink and check the ribs. The meaty ends were glistening and unctuous. The lean ends appeared dry. I decided to wrap the racks, add some apple juice and put them back on the grill. On a whim, I decided to shut down the air intake to see what it would do to the temp. After 5 minutes, the temp dropped and held at 239 for 50 additional minutes at which time the ribs were done. Me thinks I need to order a nomex gasket. The ribs turned out well, good flavor and they had a satisfying tug off the bone but a bit dry on the lean side of the rack. All in all…it was a good cook and a great way to celebrate the greatest country on planet earth’s birthday.

[Thunder77]

You mentioned that you put water in the trough. Did you do that at the beginning of the smoke also? I always start with a quart in the trough.

[Thunder77]

Here's the gasket that I got.

https://www.amazon.com/Weber-KETTLE-GASKET-Touch-Kettle/dp/B00RZSCW6U/?tag=amazi0a8-20

[7x57mm]

Hi jgjeske1; yep, I started the cook off with 1 qt of hot water.

[boftx]

I wouldn't worry about it. If you can hold a reasonably stable temp anywhere in the range 225 - 275 I doubt you or anyone else will ever taste the difference. The big worry, so far as I can tell, with high temps (> 325F) is if you have sugar in your rub. Stay under 300F and you should be fine.

[7x57mm]

It definitely stays under 300...I've had it go as high as 285 in 90+ degree, direct sun weather. It is almost like clockwork with my kettle...3 to 4 hours into the cook, the temp spikes. Most of my cooks are roasting and searing and for that, my kettle with the SnS is outstanding.

[Bruce R]

I upgraded from my trusty old 18" kettle to a 22.5" with a SnS recently. My old kettle never leaked. My new one leaks like a sieve. Was having difficulty controlling temps, at either the 225 or 325 range. Using the lid vents to help control temps was useless as the more I closed them, the more it leaks. The binder clips work pretty well on mine, and it makes temp control much easier. I use a Maverick ET-732 as well. Are you running the leads through the lid vents or under the lid? I can't keep it from leaking if they're under the lid. I had drilled a couple of holes beneath the edge of the kettle for the leads on my old one which worked well. Still may do that if I get around to it. Also keep in mind that direct sun vs shade can make a sizeable difference. 10-12 degrees for mine. Luckily it's on the deck so I can usually wheel it in or out of the sun depending on my target.

[7x57mm]

Hi Bruce; I run my probe wires through the exhaust vent. I once tried running the wires under the lid on one long cook....threaded them through the exhaust vent a couple hours later The problem I have with the binder clips are that the spring arms are too long...they hit my performer table and lid holder, essentially lifting the lid up. I'll try to find smaller clips to see if I can clear that obstacle.

[Bruce R]

I tried the smaller clips initially and didn't have very good results. If you go to a gasket, I'd be curious to hear your results. I've been thinking of going that route as well.