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I also use the wider foil from Costco and do the same thing with the crimping of the edges and I have never had a problem.

I put mine on the lid. Be sure to get the gasket as close to the edge as possible. The lid does not cover each edge consistently. Some edges you may have a 1/4-1/2" coverage and other edges it it barely covering the barrel.

I use Ez Off oven cleaner. It works fast and completely gets the grime/smoke off the first time. I also have a clean spare that I pop in when I am doing nite cooks so I don't have to wait.

Let us know for sure. I am not happy with my smoke flavor but I have not used straight hickory. I used a straight Mesquite pellet and I started to get some smoke flavor but to much of the mesquite bit for other family members. In the past I used Apple, Cherry, Pecan, Competition Blend and...