Yes, I feel like the air leaking is part of the problem but may not be the full picture. I did the same as you and put small piece of packaging foam in the battery terminal holes and it did seem to help a bit. I don't want to make problems for RBT/ryan so I can't detail much past this: I am testing the fix to my unit now in another unit. If it holds up for a few weeks we can probably put this all behind us with the fix. The test unit with the fix works amazingly at ~60% with no need to restrict draw which is a huge difference from the other which takes 75% or more and heavily restricted draw to work the same. This test unit I am very happy with and it is working like I imagined.