Sounds to me like your one-touch assembly is not seating properly. Did you disassemble it and clean the gunk out between it and the kettle bottom? If you did, you needed make sure it was bent back to the right shape to seal before you reassembled it.
Jim - Another transplanted Texan
Former KCBS CBJ
Large and Medium Big Green Eggs , Black 18.5" WSM, Blue Weber Performer - Stainless, Green Weber OTG Kettle , Brinkmann SnP Pro, and a Stainless UDS. One retired Portable Kitchen grill.
Red Thermapen, Maverick ET-732, EdgePro Apex Sharpener.
Avatar is the original 1951 Weber Kettle