Chainsaw

First welcome to SMF, you have found the right place, like minded smoke pit masters. It doesn't matter who makes the pit, we all just want to cook some great Q.

Addressing some of your points..
•Why would there be hickory wood chunks in your water pan? Did you really burn a hole in the water pan, instead of the chip tray?
•The use of charcoal, a lot of us use a briquette or two in an attempt to produce a smoke ring. Personally, I have used briquettes quite a few times and the results are not consistent. In fact I have rarely produced a smoke ring using 2 briquettes every 40 minutes for first 3 or 4 hours, so I'm not sold on their use, but the chip tray in my 40" SS MES is pretty heavy aluminum I think, and I wouldn't worry about 2 briquettes burning a hole through. UNLESS you get moisture in the pan and it sits for a long time and gets a rust spot. This has happening in my Weber Genesis Silver B, after 10 years the drip tray rusted a tiny hold thru due to corrosion.

• Yeah foil on the cooking racks is a problem, unless you make sure there is a way for the heat to bypass. So instead of foiling the whole rack leave about 2 inches on the sides for heat to pass around. If there is no way for the heat to bypass you risk a fire. The older MES had to be recalled due to a design flaw that when you openned the door the wood would combust you would get flames if there was any wood. The wood smoldering would get that rush of oxygen and combust when the door opened. If you foil the shelves this could happen again.
Really there is no need to foil, just get a can of Pam spray and give the shelves a good doze before using. Clean up is simple, just keep some Brillo Pads handy to scrub the stubborn meat bits, and wash with those plastic scrubbers, then put in dishwasher. I have left racks in for a few days either forgetting to clean or too lazy to do it the next day, and they always clean up nice like shiney new.

•Sorry your digital controller died. It happens, some here have had similar bad luck, and then some of us haven't had any problems. My was purchased June 08 and so far going strong. Hopefully your replacement will give you years of service.

As for taking the controller off if you store your MES outside, I'm not sure about that,even though Masterbuilt said it. I live in Sacramento Calif. not humid, only moderate rain, I keep my MES in the backyard under the house eve, covered with a full cover, it sits on a stand about 13" off the ground. My MES has sat there year round rain or shine, cold or hot. I do always unplug the electric cord from wall outlet after use. I think the recommendation to remove the controller could result in other problems. The little controller male/female connectors for the wiring is not made for 300+ pulling apart and reconnecting, thus you may be creating a problem rather than solving. The only thing I did beyond just using the cover, was during the worst months Dec Jan and Feb. I wrapped a thin plastic tarp over and under, secured with bungy cords.

Even though you had an initial problem with the MES, Masterbuilt did its job and supported you, (based on your comments above). Just rem. if you have another major failing, you can buy another digital controller which is better from another source, and you are back in business. The MES cabinet should be able to give you 10-20 years of service, even though you may have to replace elements, controller, etc.

Dude, out of curiosity for now, not that I need another controller at the moment, what digital controller for replacement are you referring to and from what source?

My MES stopped heating during the last smoke and I believe it to be the wiring issue at the element. I just haven't had the time to tear into it to fix. Even with this problem it isn't a biggy for me to correct the problem, and I still like my MES 40". Maybe I can squeeze the time to check it out this weekend.

Thanks in advance for the info
Matt
aka Rocky

Creative Rock...
You wanted to know about my reference to a better controller.
Auber Instruments sells PID controllers that can be used for smokers. Email their company, explain what you are trying to do, and they will recommend a replacement. You will need the controller and a sensor element or thermocouple. I have emailed them about how to do a possible two stage setup, and they responded, but I'm not sure if the options they presented are what I'm looking for.

Chainsaw...
Maybe the sensor is bad?
2nd, they sold a product that clearly shows the controller installed as a integral part of the whole smoker, intended for outdoor use, and that component is not suppose to be removed like your cooking racks or water pan. (sounds like the rep, is playing backyard mechanic, and the advice is weak, if not just plain bad. IMHO) That doesn't mean in your area you might have to take extra precautions to protect the controller, that though would be your decision. The value of taking the controller off after each use would depend on where someone lives and the relative humidity/year round weather conditions. I doubt the connector will stand up to 100+ disconnect/reconnect, hell your water pan managed to get a hole after 5 uses. About the water pan, either they cheapened the water pan or you had a freak thing happen, because my water pan is very heavy duty, and should last 20 years or so. You do have the new model with window, so they may have made some other changes, i.e. gauges of the metal.

Anyway, good luck with your MES....

Thanks a lot for the info DD. After looking at the front page of that website they are definitely a viable option, and probably cheaper than replacing with the original manufacturers part.

Even though I have my offset for smoking, I do miss the convenience of the MES. Hopefully I can squeeze in the time to tear into the MES tomorrow, because Monday I have to make a trek to Hayward and back to the Pines to pick up a couple of ebay wins.

Thanks again,
Matt
aka Rocky