What are you cooking and how often do you clean it? Also how hot are are you cooking?
It could be several things, clue us in a little more on your process and what you are cooking.
I foil mine and change it after weekend of cooking. I know Todd goes longer than that without any problems.... but I would say it depends on what you are cooking.
You do need to keep it somewhat clean. For example, I used Eddy's in FL, after he done several days worth of demo pork cooks on it.... so it was very dirty. The drip rail caught on fire where there was grease build up. It was definately due to it being dirty....
There are some folks that have had other issues, but I have not. Bill is the man, but do you think it is just a maintenance issue?
1. What temps are you cooking at, and do you use the hold feature at all?
2. What volume of food are you cooking, and how often do you clean out the grease?
3. What kind of pellets are you using?
4. What software version pops up when you flip the IQ4 controller on?
Andy /Smoke on Wheels Competition BBQ - www.smokeonwheels.com