IS YOUR KAMADO “AIR TIGHT?”

INSTRUCTIONS FOR NEW SEAT FOR BANDS

The result of this estimated 2-hour effort is a precise channel or seat for the bands to fit into. This “seat” will make the walls of the base and lid perpendicular and provide the entire 1-1/2 inch bandwidth to mate with the channel. When the bands are firmly seated and there will be no tendency to slip either up or down resulting in and maintaining the “airtight” seal between the lid and base. All earlier Kamados have slight taper in the band area that is necessary in the production process. With this taper in the walls of the lid and base, the bands do not have a full 1-1/2 inch mating surface. While a new seat is not necessary in most cases, it is a solution to a 40-year Kamado (and other ceramic cookers, as well) problem of bands slipping and allowing air leakage. This will require a bit of work on your part but the result should be worth the effort. All Kamados shipped since March 15, 2000 have the new seat and not require this modification.

We will provide a simple material kit, at no charge. There is no technical expertise necessary. A friend would be nice, as it is necessary to remove the lid. The tools necessary are two 3/8-inch wrenches, two “C” clamps (or other clamping device), thin rubber gloves, putty knife, mixing bowl, sponge and rags. The front bands themselves are used to form the precise channel (seat.)

· First lock down the stoppers on the props (the T shaped items on the tubes). Tighten them VERY tightly so the springs do not cause the band open after you remove the bolts. If you have some clamps on hand to clamp the two "ears" (prop supports) together. You might even safety wire the bands as an extra measure of safety.

· After the props are secured you may remove the bands by removing the pair of bolts on each side. Be careful when removing the lower bolts - the band will fall off if you do not hold it.

· Now carefully spin the damper top off, being sure to not allow it to fall off when it reaches the end of the threads

· Next, with an assistant, you will remove the lid and place it, chimney-side down, on a cushioned surface, such as cardboard. Be careful not to knock it over after putting it down, as it will be a bit unstable. Be careful, as it is quite heavy.

What follows is a description of the steps involved to build up the band area with the strong adhesive material supplied, to remove the slight taper. We will use the 2 front band pieces as a template to mold the seats in the lid and base. This will be a two-step process since there are only 2 bands. First, with the base (or lid) and then with the other when the first has set up.

· Clean the band area with the putty knife by scraping loose material.

· Mix the powder and liquid to form a paste with the consistency of something like peanut butter.

· Apply some light oil (like inexpensive cooking oil) to the inside of the 2 front bands (this will keep the adhesive from sticking to the bands).

· Now, with rubber gloves on your hands, apply a coat of adhesive (about 1/4" thick) to the band area of the lid or base

· Put the 2 bands around the band area over the adhesive and secure them with 2 bolts. Make absolutely certain the bands are flush (level) with the top (or bottom), that is, the bands are not above the lip of the lid or base. Tighten the bolts until the adhesive starts to squeeze out the top.

· With a putty knife you can fill in any spaces between the bands and the lip and also remove excess the excess adhesive that has squeezed out. You may also wish to use a sponge or damp rag to clean off any adhesive that has gotten onto the tile or the outside of the bands.

· Allow the adhesive to dry for a day before removing the bands.

· Repeat the process of the other lid or base of the Kamado.

· After the bands have been removed you may clean the bands with water and a damp rag.

· There may be a raised area remaining where material had squeezed out where the bands were bolted together. This may be removed with a putty knife and/or sandpaper. This will make a perpendicular channel exactly the same as the bands and level with the lips of the base and lid.

· The new channel for the bands can be grouted with the matching tile and grout color. The grout is thinned with water to a thick paint able consistency. We use a through away paintbrush.

· When the adhesive is completely dry (2 days or less), you may re-assemble your Kamado.

As you will see, there is very little chance of error in assembly or adjustment necessary to make the Kamado “airtight.” Also, there is no tendency for the bands to slip, as there is an excellent wide surface area for the bands to grip the walls of the Kamado.