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I just rake the ash out of the air inlet under the door. Yes the door is dbl thick I plug welded the cut out to another piece 1/4" that is 1" larger than the opening all the way around. I like the look and having a extra thick door to keep it from warping any at all from the heat.
I build them with 1/4" thick steel and they heat up quick. Then I adjust the dampers to restrict the airflow and let it cool down to my cooking temp. The best way I have found to keep the cc at a even temperature from end to end is to bring the intake in above the cooking grate with a deflector...
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