The more I look at these shots, the more it seems to me that the whole idea of using flavorizer bars and opening up the firepot more to the grates is inherently going to cause ash to fly up and out. The more traditional pellet grills have much less opening and a large enough shield to block most of that. Of course, the flavorizer open design is exactly why the SmokeFire can rev up the heat and make a fiery, searing show of grilling steaks.