What I ended up doing was carefully bending the lip with some pliers. So now it is actually flush to bottom of the barrel (or a nice seal) but I have no problem opening/closing the lid; nothing is rubbing against the lid and barrel. I'm digging this somker and the mods were easy. I did do the high temp silicone seal on the front which is working well and then for the sides i have the high temp/food safe silicone tubing that I slit and fit on the sides. So some smoke leakage but not much. I bought this to replace the stock thermo; not the best but its prettier but does have a short stem. I did do the 2 thermos at the grate level mod where I take my primary temps but wanted something to look at other than the crappy stock thermo. I knocked the glass out of the stock thermo, drilled a hole and put this thermo inside the stock one. Works fine.Yes, I have that much gap. It changes depending on how much lid is open or shut because the hing isn't exactly on the axis of the back of the smoker.
I would think if you took a needle nose pliers and gave it a few light crimps it should take enough flare out to fit the 3" hose over it..... just my thoughts thinking out loud I guess.The bottom of my stack is flared out. It measures 3 1/4" and the 3" tubing won't fit. Anyone else have this problem? Any idea's?