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Thanks for the comments, Groucho.
That said, a few tidbits for you:
1. Repaint while you have it all apart. Last thing you want are rust stains flowing down between the CC and FB.
Absolutely, paint while apart. That's a given.
2. Reassemble the CC and FB upside down. Let gravity work for you, instead of against you.
I'm not sure what you mean by upside down. I'm now using a plastic milk crate and some boards to get the FB up to where the bolt holes line up, then sliding it into position. For the final assembly with the gaskets in place, I'm considering putting the support on a little dolly on castor wheels so I can roll the FB into position, much like how jet engines are installed in airplanes. I don't want to dislodge the gasket during the final assembly and the FB is heavy, requiring a bit of wrestling to position it.
3. Do not use nylon locking nuts on reassembly, as they will melt. Go old school: nut, bolt, washer, lock washer when putting back together.
Of course, no plastic, rubber, or nylon.
4. 3/8" rope may be too thick for what you're looking to do. Like I said, reassemble upside down, and cinch the hell out of the nut/bolt assembly: all I ever used on assembly were sheets of foil as gaskets that were compressed upon attachment, and nothing more was required.
As I said in another post, I found that only the bottom three bolts had been installed to attach the FB to the CC. The ends of the two chambers are not flat and don’t mate up properly, creating areas where there is essentially no gap and areas where the gap is ~3/16" wide. The rope I have is 3/8" dia. and will compress to about 1/16", so I'll let it compress where needed. And I already have ALL the bolts and nuts (6) to install this time. The use of foil is interesting. I may go that route if the rope doesn't work out.
5. Make sure none of the attachment holes are missing the nut/bolt assembly. Often, this is found when these rigs change hands, and all that's needed are to get more nuts & bolts, and tighten as much as you can. In fact, you can drill a few more holes and add more to keep it all together to minimize smoke/heat leaks.
All holes are plugged with something; nothing is missing.
6. The old school legs had a plate spot welded into the tops of each of them. These plates had threaded studs that protruded, and went through holes shot in the bottom of the CC. If you don't have them, get some struts that go at a 45* angle from each leg and attach to the CC. They don't have to be more than about 6" long, but they will keep the stress off those little spot welds in the tops of the legs while you're moving it around.
I don’t see any spot welds; the legs and reinforcing plates are all bolted in place. The smoker seems to be solid and rigid with no flexing. I'll let it be (for now).
7. If you don't have one, look at this link:
http://www.smokingmeatforums.com/t/89796/i-call-it-the-20-20-charcoal-basket It will help with temp control as well--make sure that you keep it off the bottom, and keep the ashes cleared out underneath for efficient airflow.
I plan to burn wood for now, but will probably add a basket for charcoal later
While I haven't found a need for a Guru on this rig (don't care to have ash blown all over the CC and I can easily control temp without), I suppose if you had one, you could run with it. I just haven't found a need to go buy one, as I can control very easily by simply opening or closing the FB door more or less to throttle. Note: door, not damper. Damper is fine tuning, door makes wholesale changes. Enjoy your new toy--these are good rigs, although it may take a little time to dial it all in. Have a little patience, have fun, and good luck.
If I add the Guru, it will be later; I hadn't considered ashes being blown into the CC. But all reviews and info I've seen seem to say the Guru is the way to go for even temps. And the idea of loading the FB with wood and getting a good night of sleep appeals to me. Good comment on the door vs. the damper. My plan is to put it back together, fire it up, and play with maintaining the temp. Then do the final painting.
I still have to make the usual modifications; installing a second thermometer at the grate level, extending the stack down to grate level, and fabricating a heat baffle from the FB. Some reports suggest extending/lengthening the stack for better draft. We'll see. Also, there is a significant gap between the stack and the shell of the CC. I guess I'll seal the up while it's apart. Otherwise, what's the point of extending the stack for better draft if it leaks at the CC?
I've read so much by Aaron Franklin and others and watched so many videos my brain is full and so I'm ready to start cooking. Wish me luck.