I recently had a crack across the plastic top of my FreshRoast Plus. As usual, Tim at Fresh Beans came through with a replacement sent very promptly. The roast chamber base was always a tight fit, and I might conjecture that could have been a contributing factor to the plastic cracking prematurely. I asked Tim if I might help matters by using some emery paper on the rough surface of the aluminum base of the roasting chamber.
He said to go ahead, and it now goes in and out easily.
Now the slight problem. My house voltage has been on the high side lately as measured with my KillaVolt.
The open circuit voltage said 125V and under roasting load is in the mid 121's. This morning, I roasted some Costa Rican Dota with my usual method of going until first crack, cooling for 15 seconds and then going back to roast until the desired degree is reached. The time until 1st crack was 1.7 minutes and the second round was only 1.5 minutes. This seems too fast to me. Perhaps I shall try adjusting the slider on the variable resistor.