McGurk
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If you are an inch short on the diameter, that kettle ring is going to fall right to the bottom of your drum. For fitment, flip your kettle bottom upside down and see if it will slide down the drum. If so, you may want to stick with the flat lid for now. Another option you could try is to meld the flat lid and Weber lid together, and then cut out the inside of the flat lid to have a "super-lid." I've seen it done in this thread but don't remember where.
Yes, you will need to remove that foam gasket. Use a light solvent (some say WD40 works) and soak it up good and let it sit a few hours. Remove what you can and reapply solvent. You want it all out. You can torch out any last remaining bits, but don't warp your lid by letting it get to hot.
Yes, you will need to remove that foam gasket. Use a light solvent (some say WD40 works) and soak it up good and let it sit a few hours. Remove what you can and reapply solvent. You want it all out. You can torch out any last remaining bits, but don't warp your lid by letting it get to hot.