If you have no issue with wind blowing real bad through the intakes, I would probably chalk it up to the wind causing more coals to light when you removed the lid. On mine I can't operate fast enough to stop flare ups so I shut my intakes down 3 or 4 minutes before opening lid and not opening them again for a few 3 or 4 more minutes after replacing the lid.
Hope it all works out for you in the end.
Take care!
Ray
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UDS | BP UDS | Weber OTS | Weber Smokey Joe
Never be afraid to try something new. Amateurs built the Ark, Professionals built the Titanic
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