@USMC615,
Jason, I found the same problem with the legs. I decided not to drill them and add casters. At least for now.
I had to seal the stack on mine as well. The flange and pipe weren't square. I had to straighten that out. When I did, I ended up with a big gap on one side. I sealed it with food grade high temp RTV. I also sealed the joint between the flange and the cabinet.
View attachment 42112 I've got the gasket material on the cabinet and burn chamber, just waiting for the adhesive to set up. I looked at the joint between the two and am going to seal it with either a gasket or RTV. I found the gasket material locally, for $1 a foot. I'll probably use it for the seal between the two pieces, in case I ever need to take it apart again.
Although not specified in the instructions, I bent the tabs holding the bases for the chip trays to keep them from moving.
I'm assembling mine in the house. It's a little chilly here and I wanted to watch football while I worked on it.
Here's a shot of the mess. The main cabinet is on the island in the kitchen.
View attachment 42113
I showed my wife the pics you posted of your assembly. She says we're a couple of Anal Retentive over engineering idiots.
Yep, pretty much so.