You can try loosening those screws and seeing if you can then adjust the door in/out or up/down.
It used to be that things like that were adjustable. Lately they make things cheap and you can't do that.
I modify things like that so they work properly. Make my own bracket or drill my own holes - whatever. I buy these things lately and they don't work properly out of the box. Glad I know how to fix things!
Note if you do not have the tools to make your own bracket, a machine shop may be able to do that for you. Tell them the problem and say you want to be able to adjust it.
Doesn't appear from the pictures to be misaligned particularly--the gap along the right hand side is uniform from top to bottom so it's not askew.
It would appear more likely the in/out alignment is off so the gasket isn't compressed. That would require shortening the hinge length.
I'd wait until had the new door before worrying--if there's a manufacturing defect in the first that the replacement solves, then no problemo. If the new doesn't fix the problem then use winding stick method to see if the face of the opening is, indeed, coplanar.
You can't? Then what's the roundy strip between the door and the smoker body? To my defective eyes, that looks like a gasket.
When I measure with my tape on screen with your pictures, that door seems mounted perfectly parallel with the body of the smoker. Have you checked that distance with your tape?
I have a suspicion that the entire hinge-area is too far away from the smoker, and the staining is happening at the top only because smoke rises.
Open the door with your right hand. With your left hand, insert a piece of paper at the top of the door, between the door-gasket and the smoker, where the staining is. Hold on to the paper.
Close the door with your right hand. The paper should end up trapped between the door and body. Now slide that paper downwards. Is it really loose until it hits a certain spot, or is it really loose all the way down?
Doesn't tell me much, unfortunately, except that the door seems straight left-to-right as well.
HomeOwnersHub website is not affiliated with any of the manufacturers or service providers discussed here.
All logos and trade names are the property of their respective owners.