I have been struggling with the idea of obtaining good seal, without using hi-temp silicone (cancer warnings suck) or the rope seals that don't stick worth a dang and people complain about. Today, I used a stove and fireplace sealant by Red Devil. Rated for up to 1200 degrees. Though it goes on like a putty and is a little stiff when working with it, it truly works great. I was concerned that it would not work very well when I first got the product, because it came out like a rock-hard dry rod when dispensed using my caulk gun, so I called Red Devil. The lady at Red Devil took the batch number and said it only has a shelf life of 6 months, I told her I bought it the week before and it was hard in the tube to the point it would not dispense from the caulk gun, so they went ahead and sent me two brand new tubes. New tube went on pretty good, almost like a flexible plumbers putty, but you mash it to the door lip, spreading it out evenly with your fingers. I coated the lip of the cook chamber rim with olive oil on a paper towel so the product doesn't stick and then closed the door to make an impression on the seal. Anywhere there was no door seal impression, I added more and re-seated the door again to the cook chamber body. After a few passes, I had a good seal. Once the product is set where you want it, you fire up the firebox and heat the seal for a couple hours to cure it. Needless to say, it works great. Though my smoker is a very recent build, my door disappointingly always leaked on the top and bottom. As of today, no more leaks. I am very pleased with the results. The product costs about $12 a tube, one is plenty sufficient for a 120 gallon or smaller cooker, unless you have monster gaps. I only used 2/3 a tube and I went heavy on the seal. For two door smokers, I would buy two to make sure you have enough. I bought 2 tubes just so I know I won't run out, but I was good. Ended up giving the second tube to a buddy who has a Brinkmann that leaks, so it didn't go to waste. Images speak better than I do, ask any questions you have and I will help any way I can.
Lastly, you guys so ROCK! The support, the idea sharing, the recipe sharing, the deep thoughts you guys put into these designs, absolutely amazing.
You guys are like my bbq brothers, thanks for everything!
What the seal looks like when mashed flat and sealing properly:
The joy of what no leaks looks like:
TBS rolling, cook chamber sealed well, product cured. Works great! Hopefully it will stand up to the test of time.
Smoke well, my brothers.......
Edited by PCJack - 10/15/16 at 3:48pm