Carl, I'm pretty sure that putting charcoal in with the chips will solve your problem. I use a brute force approach-light the Big Kahuna with a blowtorch, from the bottom obviously, and then leave the bottom and top caps off until I have a nice hot fire going. Add a few more chips, replace both caps, and only then plug in the aquarium aerator and start smoking. If the fire dies down at all then remove the bottom cap for a minute or two. Incidentally liked your big loops in the piping setup; these will work great to trap the smoke condensate.