Just got off the phone with Dennis. I went outside and took the grill apart with him on the phone. I had done this several times before so I knew the funnel system was seated well, but what I DIDN"T do was take my big head and get really close to the left side of the flame zone. There, in the middle it was raised up just a bit. Now, when I put the flame zone back on I look for the F, I place it on and slide it left, right, forward and backwards to make sure it's in place. All seemed well.
HOWEVER, after sticking my fat head in there real close I noticed that even though it felt in place it was actually catching on the back left lip of the funnel and raising it about 1/8 of an inch. I lifted while pushing and bang it sank right down.
TOTALLY MY FAULT!!! Thanks to Dennis and MAK for being so nice and walking me through this. I am usually really REALLY technically savvy, but I'll be danged if I wasn't eating a sack of idiot sammiches on this one.