Side Burner HUGE Flame - Help!

[John-NY]

Grill is a Spirit E-320 LP

It has a side burner, and the flame is giant.

I've completely deconstructed, cleaned, and reconstructed this grill, and confirmed the orifice looks to be its original LP orifice.
The main burners output perfect blue flames without issue.

I've never seen this before, and can't figure out what the issue would be.
Anyone have any ideas for the cause?

 

[Jim Weber]

Honestly --- that looks like a rather large orifice for a LP burner to me....

 

[John-NY]

Honestly --- that looks like a rather large orifice for a LP burner to me....

So, I did realize that in the photo I looks big, but in real life it looks small. I have a duplicate grill in the shop I realized I can compare the orifice to and report back. But beyond that, still a mystery to me.

Edit Update:

I confirmed from my duplicate grill that the orifice is the same size in that grill and that one's side burner does work fine:

 

[timothy]

Is the disc/diffuser perfectly centered over the burner tube?
I know if mine gets jostled the flames get pretty wonky.

 

[John-NY]

Is the disc/diffuser perfectly centered over the burner tube?
I know if mine gets jostled the flames get pretty wonky.

Yes, it is, and I just did some more experiments.

I swapped the disk with the other grill, but the results were the same (I was wondering if there was a coating on the disk itself making it flammable).

I confirmed 100% that the other grill side burner works perfectly as expected.

I'm going to go try to swap to a different regulator and see how that goes.

Edit Update: Not the regulator. I’m going to pull out the valve/cone and have a look.

 

[John-NY]

Cleaned the cone, still big flame.

So I think I figured this out, but now wondering how to clean it.
My guess is that something boiled over and flowed all down through the gas pipe. Here’s a picture I’d the top down of the ring, and looking straight into the front of the gas pipe.

Any suggestions how to heavy duty dissolve/clean that out?