Bugsdog - I had the same problem with my AmeriQue; in addition I was experiencing wide temperature variations while smoking. After doing a search and reading a few other posts on the forum, I started by removing the controller and found a great deal of moisture on the interior of the controller. I then removed the entire back panel and found that much of the insulation was quite wet and, in addition, the insulation towards the top was smoke stained. This is caused by the top back seam of the interior compartment being only spot welded in a few places; moisture and smoke escapes through this unsealed seam. I called Cookshackâs first rate customer service and spoke to Bill Vice about the problem. He shipped me a new controller and replacement insulation. I bought a tube of high heat silicone sealant and sealed the top back seam while waiting for the parts to arrive. When they arrived I put everything back together and was good to go. During your first smoke after reassembly I recommend leaving the controller detached and slightly off to the side just in case there is any residual moisture in the top insulation that might come up through the holes in the top of the case. Hope this helps.