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Note: Leave the exhaust stack vent ALL THE WAY OPEN. Always. Control combustion using the intake vent. A closed exhaust vent can facilitate creosote buildup and nasty-tasting BBQ.
Don't put lava rock -- or anything else -- on the bottom of the smoker. You'll just mess up draft/flow. Check out my gallery of pics. I made a deflector from a cookie baking tray I got from Target for $12. Works great. I've written about it several places here.
Use more fuel. I'd recommend mesquite wood chunk about the size of baseballs/softballs. That'll get you the therms you need and the great smoke flavor. Here's the size I get (compared to a Kingsford briquet).
It's essentially more of a fuel mass problem than a heat retention problem. On cold days, get rid of that little smokenator setup and just bank your coals behind a couple firebricks laid slightly overlapped and then wrapped in aluminum foil and used as a barrier. Works great. Here's what I'm...
I strongly suggest leaving the paint out of it. After a smoke, just get all the ash out (I use a cheapo 3" paintbrush from Harbor Freight to help with this), then you can spray/wipe with some Simple Green. Let dry, then spray a coat of non-stick cooking spray on the inside and wipe it into the...
For those folks that use the firebox's existing lower grate to set your charcoal box on, I recommend using bolts to lift the grate up some off the bottom. I gives much better air flow and a lot more room for ash accumulation.
You don't want the wood to smoulder.... you want it to burn. Put it right on your hot coal bed. It's the gases from combustion that contributes to the "smoky" flavor we're looking for, not the billowing white smoke that arises from inefficient combustion.
The flaking is a result of a poorly applied and cured -- or improper -- paint coating, not excess heat. The side firebox on an offset smoker needs to be able to get HOT, like 700F hot. Steel thickness has a lot to do with it, but you can't change that. Just scrub off the flaking stuff and...
Here's my 18.5" Weber One-Touch Silver. Got it on sale at my local Target for US$52. I use it 3-4 times a month and only do indirect smokes on it. I bank my coals (via the minion method) and wood chunk behind two (slightly overlapped) firebricks wrapped in aluminum foil so they stay together...
The temp drops precipitously as you move the thermo reading down the sides of the FB. By the midpoint (where the two halves join), it's probably closer to the low 600F range.
I've hit the FB outside top with a digital laser thermo during the middle of a cook (cook chamber was holding at ~280F) and registered temps just shy of 700F.
Sooting and/or creosote buildup is usually caused by a lack of proper draft, i.e. running your smoker with the exhaust stack even partially closed. Also, if the wood/splits are still laden with moisture, combustion gets degraded, and you're more likely to suffer creosote buildup. Make sure to...
Pork shoulders won't take that long. You would have been fine getting a good nite's sleep, then getting the fire started at say 0500-0530, take 45-60 minutes to get chamber temps stabilized at 265-285F, and then get the protein on. You'd have plenty of time to hit an IT of 200F on the smoker...