Update - I installed a new Weber regulator (it's been redesigned) and the grill works again. I'm not sure if the grill has EVER worked this good! I have nice tall blue flames shooting out of all of the holes (yes it was clean with the old gas regulator as well). Now I just have to worry about the plastic frame. The heat from the cast alum bottom "bowl" thing is melting it's way through the plastic frame and I don't use this thing for long cooking such as tailgating, etc. where it could be on for hours at a time.
Oh well ... at least it works now!