qweaver,
sorry to hear your problems, i have a breckwell pellet stove.just love it to address your first problem of cleaning everyday, change the brand of pellets (to many fines) good hardwood pellets won't give you much ash. i clean mine once a week. when running on low setting you need your damper shut all of the way , 2-3 setting have your damper set at half open, your flame should look more like a blow torch than a lazy flame. the first thing i would do is try a differant brand of pellet, good pellets will make most of the other problems go away. far as making noises, is the stove sitting flat so one corner isn't touching this will give viberation sounds, adjust your hinge so it fits up flat so the magenet holds.if nothing helps fix the problem let me know i know people that can help.
i'm no way associated with breckwell, in fact i had never heard of them until i started looking for stoves