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Have you ever removed the fire pot and vacuumed it out inside the air duct? I haven't ever seen this happen on either one of my FEC 100's but If I don't vacuum out the Traeger good every 60-80# of pellets I get some excessive ash buildup that will cause some smoke to come out of the fire box. Should just be a couple of small(1/4" or 5/16") screws and it will slide out to the right.

I always vacuum out the fec fire pot each time I use it and try to remember to have the fan running on the smoker while I do it. I remove the pot every month and clean out the extra ash that gets under it but I use mine at least 5 days a week. Just make sure when you put it back in you get it in tight or this will mess with the air which can cause other issues. I put a long hose clamp around the left side to help hold it tight.

Do you have a stack/chimney attached to it? Guess it could get enough buildup on it to restrict the flow but that would be pretty extreme.

One other question... does it have a flat bottom stainless fire pot or the angled cast pot?

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