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I would probably do the cook chamber door, but only do the firebox door if it really fits poorly. If you can shut the firebox vents and choke the fire you don't need a seal. It takes time to feel out your vent settings and how much fire you really need. Good luck and keep at it.
Getting ready for this weekend already. Going to be smoking 11 Boston Butts with an average weight of 9 pounds each. This will be the most butts I have done in one smoke. Should be fun.
If you do a decent job on the firebox door you shouldn't need any seal. If you look at most high $ smokers they do not put a seal on the firebox door and their vents don't look nearly as nice as yours.
You could just weld a small tab at the bottom of the door to hold the hinge, Just smooth the edges so it looks like it's supposed to be there. When it's done nobody will even question it.
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