Cam,
You obviously have a great deal invested in the success of this endeavor. I agree with Walt that you will definitely have a niche market, as I alluded to in my post. After thinking about this some more, I wanted to add a couple more thoughts...
First, the cost of shipping will be a factor for many, due to size and weight. Yes, the cost to ship SI smokers seems hefty, but you're paying for protection and speed. These are big boxes, very-well packed, and contain fragile components (nobody wants a dent in their stainless skin). Your grill couldn't hardly get damaged no matter how it was shipped, so the cost is solely based on size and weight. I didn't explore shipping costs, so this is just a thought about the subject based on guesstimates. Like you said, it's perceptions.
I would maybe consider different size options. I consider myself a "serious backyard cook," but don't buy products that don't fit my needs. Yes, it would be cool to have a Model 4 SI (for bragging rights alone), and I'm fortunate to have the means to have one, but it simply does not fit my needs. I would not want to deal with deployment and storage of a hunk of steel that large. If you had, say, a 16" or 18" model, I could possibly see myself interested. So, my lack of interest in the product is not based solely on cost; it's more about need. With that said, I believe there are many others, in the target markets you mentioned, that would be well-suited with a grill that large. It would also add different price points to the equation.
About the "Made in America" issue: I absolutely applaud your desire to have your product produced here! At the same time, I understand business owners' decisions to produce their products offshore. We live in a very competitive global marketplace, and, sadly, America has a hard time competing. SI smokers are built in China. While I would prefer they were made in the USA, I fully understand Steve's predicament. Is the quality any less? I don't think so. Mine is well-built, and works great. I am sure that producing the SI in the US would probably double its price, and push it into the Cookshack price range. Would I buy one at twice what I paid? A solid "maybe." There are definitely other offshore options than China. South Korea (actually Hyundai) is one of the largest steel producers in the world, is an ally of the US, and a free nation. Who knows, that may be worth exploring. I personally don't think your customers really care where the product is produced, as long as the quality is what it needs to be, and it functions "as advertised." Unfortunately, we (as a Nation) have priced ourselves out of the manufacturing markets due to so many reasons I won't bother to get into. Here's an example - about 10 years ago, a large highway bridge was built in Arkansas. All of the massive I-beams were marked "Hyundai" on them! It was actually cheaper to have them manufactured in S. Korea, ship them here on Hyundai container ships, and trucked to Arkansas, than it was to have them produced in Pittsburgh! Sad, but true.
You mentioned, you could have gone offshore, but that's "not how I roll." Unless you find a manufacturer who is going to be competitive with other countries, I would urge you to reconsider your position. Until your patents are secure, you can bet that a competitor or two is already figuring-out how they can reproduce your grill cheaper. In the end, buyers will turn to the cheaper competitor. Research manufacturing in free countries that are strong allies of the US. You don't have to go to China. Hold on - my steel fabricator buddy is calling. Be right back... (just kidding!
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I wish you the best success, Cam! Many folks, who have never attempted to start a business, don't know what you are going through right now. Keep the faith, stay strong, and above all - make sound business decisions without emotion.