Any suggestions on sealing the door? I can see it is cheap and needs to be re-enforced....
Yep, that's the 2014 model that came out the end of last year. Mine is exactly the same. Makes life so easy threading probes through that slot. I don't use the probe hole at all, just the slot. I've had 5 probes through that slot no problem.
My WSM was slightly out of round and my door was so bad there was no way to seal it. It smoked fine, just at higher temps, like 275F. What irked me though was how much charcoal turned to ash after I shut it down and sealed it off. The hot coals were still getting too much air.
After 6 mos I picked up a Nomex gasket kit off Amazon for like $25 or $30. I expect there's something cheaper you could find at HD or Lowes. I was using fun money I won at work in the form of Amazon gift cards so it didn't cost me anything. Works like a champ! Sealed it up and when I shut it down, it snuffs the coals. Sealed the lid too.
Weber listened to the users that were having to cut slots and drill holes in their cookers so they did it for us with a silicone grommet. Pretty cool huh? A company that actually listens. Now if they'd just sell the warming rack for the 22.5" Kettle in the US.
I JUST got a WSM myself about a week ago. I had a heck of a time getting the round rubber thing in just right but then I did some goofy twist push thing and got it.
I have only used it once but I just used the slot thing too. I tried a probe through the round hole part and it seemed like it was too tight going to push out the rubber thing so I just skipped it.
I have had it 'fired up' twice - once to season and then 2 days later to use. I didn't have any issue with smoke coming out of the door, but maybe I just got kind of lucky. I did get some out of the lid
here is a picture from my one time of use - you can see the smoke coming from the top lid but not door.
Here's what the fig of my door looked like when I got it a year ago. I worked it and worked it to get it to fit a little better then eventually got the gasket kit. Sealed it right up. .
wow that is pretty bad noboundries...
Mine was nowhere close to as bad. I didn't adjust my door a single inch and you can see it fits pretty well.
I still might do the seal like you did just to make it super snug.
The kit contains a roll of the Nomex gasket material and the silicone high temperature adhesive. There is enough to do the bottom, door, and lid. I didn't bother with the bottom because it wasn't leaking. Weber redesigned it a few years ago solving that problem. I have enough adhesive and gasket material left over to seal my Kettle lid, which I haven't done yet.
Basically you clean the surface, which was a bit of a challenge after 6 months of use (use a solvent, a glass scraper, then clean thoroughly and let dry). Next you apply the adhesive, then gasket material and cut it when you have full coverage. My cleaning and application took about a hour, and most of that was cleaning. It is easier to do it when it is new or has very little buildup. Applying the adhesive and gasket material took maybe 20 minutes.
Picked it up off Amazon. Search for WSM Gasket Kit. $23.50 + $4.50 shipping, not Prime eligible. Others may have it cheaper.
Actually when my smoker arrived originally the middle section was so bent up I couldn't even come close to getting the lid on, and I contacted Weber and they sent a new middle section immediately. now the top fits onto it just fine BUT now I am wondering if despite that I still have issues per your comment.
I may try 1-2 more smokes, and if I keep seeing leaks out of the lid like this I think I will call them and at least ask what they think may be the issue. I didn't realize it shouldn't be leaking out of the lid (outside of obviously the vent part)