You will have to forgive my ignorance, it has been a long time since I did the Performance Test on the 500. Am I correct in assuming you think the leak is coming from this drawer?
If so, I would pull it out and fill it with water and see if you find any leaks. If so, that could be sealed. And yes, somewhat disappointing, but fixed is fixed. The pellets, I also felt not an issue, unless it is an excessive amount. I remember just one incident on PH, someone chute was off and Cookshack did a fix for them.
And I have not felt you were crying wolf, I think you are trying to solve a problem. And this is OK.
Picture at the end of my cook showing grease problem with ash draw.