Okay... Fired it up for the first time tonite. Overall quite happy with what I found out, but it was completely empty, so I'm not sure how much everything is going to change when its loaded down with food. After it settles in, this thing was within 1-2 degrees from end to end and front to back. Top rack was 5* warmer on the end away from the firebox, and the biggest difference I could find was 11* on the 'fill in' racks directly above the firebox and below the flue.. I wasnt even going to fill them in at first, but i figured I was just wasting space if I didnt so I went ahead and did it.
Things I learned..
1.) It takes a long time to get these heavy builds up to temp. Especially with the extra plate. But once it settles in, man is it even compared to what I'm used to. It also doesnt adjust all that well to temperature changes.. Its awesome if you want to cook at one temp (which i usually do), but say you want to start at 225* and finish at 300*, it takes a little while to settle out. And you dont want to get it hotter than where you are wanting to cook for sure.
3.) I definitely have to get my door sealed up better. Which isnt going to be fun. I was extremely careful about keeping the heat down when i cut it, but it still popped out about 3/8" on one end and 3/16" on the other. I'm thinking maybe the rolled tank had some pressure on it when it was welded. Next time I will just cut the door with a torch and fit it before i weld the hinges up. Since its already hinged its going to be a nightmare to fit. But I think I'll manage one way or another.
4. I think I'm going to hate the removable ash tray. The idea was great, but I think I just made it a little small. Next time I will definitely allow about 4" and put some 2" sides on it. I dont think it will ever hold the ashes from an all day cook. Hard to figure out how to stuff all these features in a small tank like this and have room for food and fire. Live and learn I guess, the TBS will still flow...
And yes, I was a little worried about the plate being too close to the food.. But not after firing it tonite. The extra space between racks was well worth the risk IMO.. I've seen builds on bigger tanks this close so I just decided to go for it.. The closest point is 4", which is at the chamber wall on the firebox end.
More pics tomorrow hopefully. It looks much better with the handles done and a little cleanup on the tank.