TravelingJ
is One Chatty Farker
If you are going from a wide open fire box door to completely shut that may be your problem. It is best to close the door a little bit at a time. For example, when I put a new split or two on I will start with the door wide open for 5 min or so. Then move the door about 3/4 for a few min, then 1/2, then 1/4, then open latch, and finally closed. The whole time keeping the pin wheel dampers wide open. This keeps the draft going properly and prevents smoldering due to quick changes in air flow. Of course wind plays a factor and I adjust my technique as necessary.
Also, when starting the fire you may be using too much charcoal. I use about 1 chimney and 5 splits and a lpg torch to start it.
And people say a PitBoss has a complex startup procedure..