Hi Dave - Thanks for the great input. I think your latest pics have helped me. I see two things that are causing problems at the moment.
1. My intake air intake has 2 large openings 3 x 3. so wide open I have ~ 18 sq in area of intake and the exhaust in CC is a 3" pipe which has ~ 9.5 sq in area to vent. Not a good match and explains why my best smoke is with vents 1/2 open.
2. My Smoke exhaust chambers from the FB are on the sides of the CC. The smoke exits at the top of the box on each side from 2 1/2 x 7 openings. That's 30 Sq in area of smoke exhaust to CC and only the 3" pipe exhaust from CC.
Thus I think the main issue is the Exhaust is way too small. Now I can add another 3" exhaust or increase the D of the existing. Either will be a pain as I have everything insulated and tile boarded but doable.
I also think I need to reduce the size of the smoke chamber exit size at the top. Maybe Aluminum tape off by a half. Would like your opinion on that for sure. Just getting way too much smoke volume and respective heat. This also begs the point of adding a couple ports from the side smoke chambers ~ 1/3 from bottom of CC. Maybe create a venturi like effect to help with circulation.
ALSO - I tried to draw a better pic of the mechanics of the Smoker to help you understand what I have done. Sorry about the scale not being the best.
Adding more holes to door is a pain as well as it is 1 1/2 " thick with insulation between 1/8" skins over tile board. But I need to get this working better. Adding a fan is not preferred if possible. Just a thought about mixing up and moving the air to the bottom with a fan at the top.