What is the best way to clean the mesh?
I keep a small wire brush in my case to clean the grates while they are still warm, like this one:
http://www.shop.mobile-shop.com/images/1203454012986328900511.jpeg
Just thinking out loud but perhaps these BBQ grills were designed more for Japanese style Yakitori... like smaller bite sized eats. That's the type of grilling I mostly see while in Japan.
I have had no problem with much thicker/larger items. The biggest issue is gauging the amount of charcoal you will need for the meal, as well as which grill you are using.
I guess my two questions would be how much charcoal are you using and how are you lighting it/bringing the coals up to temperature?
When we use it this weekend @ SyncroFest I'll take some photos of how we use the BBQ box in the field and we can see if there is anything we're doing differently?
The problem with the single BBQ box (I don't have experience with the double BBQ box) is that the fire pan doesn't really allow for air circulating under the coals. The coals choke themselves in their own ashes. I've heard of people having good luck drilling holes in the fire pan to allow air under the coals. I tried something different: I found a grill grate that was just the length and just cut the width to fit. It rests on the sloped sides of the fire pan and holds the coals about 1/2-1" above the bottom. This allows air to circulate underneath. Now, the coals will burn until there's nothing left but ash. The heat is now more consistent and burns for quite a while. I can now sear meats or slow cook with the lid on without the coals going cold.
With a good amount of coals in the single BBQ box and using the lid, I've cooked dinner and still had enough heat coming off them in the morning that I could have reheated some meats the next morning. Granted this was when I first started using the single box and kind of had a little too many coals in it. I had to cook dinner with the grates at their highest setting. After some more practice about half the amount I used the first few times will do for what ever I am tossing on there and cool down a few hours later.
As it was mentioned before, the coal pan in the single box doesn't have any bottom ventilation so getting the coals going evenly in the pan itself can take a bit longer but once you get all your coals going, it will actually help stretch the life of them in the pan and be extremely efficient. When I got the Twin BBQ Box and later the Double BBQ box, the bottom venting made it much easier to get your coals going in the pan itself. It also provides much more air flow and more even heat, the downside I've experienced is that your coals burn up twice as fast. This took a little to get used to and by increasing the amount of charcoal I found getting the entire meal cooked is not a problem.
I guess you need to consider which one will suit your needs best. As someone who owns all three models (BBQ Box, Twin BBQ Box, and Double BBQ Box) and have used them quite a bit, I can say from my own experiences that all three perform very differently from each other, all have some great points, but all have some not so great points in usage, storage, and portability. If you want to see some more pictures of the 2 larger grills here are some I took when I first received them:
The Twin BBQ Box:
https://picasaweb.google.com/chrisvonc/SnowPeakTwinBBQBox#
The Double BBQ Box:
https://picasaweb.google.com/chrisvonc/SnowPeakLiftUpBBQBox#