I did contact Memphis support. They reviewed my past cook data looking for any controller issues but found nothing and simply reassured me that if I use the indirect insert I should have nothing to worry about. I was a bit frustrated with the response, but I know that users do the dumbest things too. I had previously confirmed with them though that I was using the indirect insert when the fire happened (and only use the direct insert rarely and on OF mode for steaks and such).
The drip pan idea might work and I might consider occasionally for exceptionally greasy meats. However, we are severely reducing our cooking capacity if we have to frequently cook over a drip pan on the main grid and put all our meat on the middle or top shelves. My last fire was cooking 9 pounds of chuck roast at 325 on a clean grill for 4 hours. I really don't consider that hot cook or chuck roast all that greasy.
I wonder if the deflector was made with a little steeper angle? To keep grease and food particles from accumulating as much on the deflector? I might try getting mine spotless and coating it with grill cooking spray to make it a little more slick, but not sure I can keep up with that because it would need cleaned and reapplied every cook most likely. Has anyone foil lined the Memphis drip tray?
I also want note that I'm in no way trying to bash Memphis. Except for this issue, I really love my Pro. The whole reason for even starting this thread is simply to find ways to eliminate this problem since it seems to be a fairly common thing that I've seen at least a few other users mention. Hoping someone already has the answer.