I just put mine together the other night and the door was a little bent at the top, I was able to use the water pan as a guide to help me get the top curved. I used a flashlight from the inside and not much light came through. i am hoping after a couple of smokes this seals up. My issue was Weber sent the incorrect cover and they are sending me another. I called them, and they are sending me another. You could try calling Weber they may send you another.