Bit frustrated by the water getting in and the resulting mess in cleaning out and inability to reuse remaining good coals. I see elsewhere the following"
Q: Why does water collect in the bottom of the cooker, even when the vinyl cover is in place? Why doesn't the lid overlap the middle cooking section like other Weber grills?
Seam sealer
Photo 3
A: Despite what you would think, the vinyl cover is not waterproof. Water leaks in through the seams in the cover and runs down the lid, entering the cooker where the lid meets the cooking section. Once inside, the water collects in the charcoal bowl.
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There are several ways to deal with this problem. In my opinion, the best solution is to prevent water from getting though the vinyl cover in the first place. Move the cooker to a sheltered location, if you can, or place a large plastic garbage bag or tarp over the vinyl cover. WSM owner Jake McCready suggests applying seam sealer, a product sold at camping supply stores, to the vinyl cover (Photo 3). "I've used this for decades on many tents and had great success with it," says Jake. "One application lasts for years."
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Finally, if you like power tools, you can drill a small weep hole in the bottom of the charcoal bowl...not so large as to affect temperature control, but big enough to allow any accumulated water to escape.
I was thinking about the third option drilling a hold before finding this thread, but concerned about warranty void and would this cause premature rust starting at the hole. I do not have a means currently to cover my grill and it's unlikely that I will in the near future due to the limited patio space. I would consider a different cover, but again I am guessing they need to breath to keep from trapping Houston moisture inside the cover. What suggestions are out there? The water in the spent charcoal bowl is a big problem [odor, flies, mosquitoes and concern over premature rusting]. Thanks!
Also, the Weber cover included with my Weber smoker seems entirely too tight [circumference] to fit the unit. It is extremely difficult to get it over the protrusions. Perhaps having switched covers to an aftermarket larger cover wasn't in my best interests, but has been easier to remove and cover.