I've just checked the four PBS stations I get on satellite TV out here, and two of them have BBQ U listed as a regular program 4 times a week.
The bad news is that both BBQ U and Primal Grill both seem to be the first two shows that these stations pre-empt when they want to show some goofy infomercial.
As for copyright violation, I got a crash course in copyright law when my old band decided to cut a CD. Sharing DVDs of all episodes of the show would definitely be a technical violation of copyright law. But as many of you have mentioned, it also increases sales and good publicity, so this is still a grey area. I also know firsthand that CD sales plummeted when the RIAA clamped down on downloaded songs, as opposed to the early days of Napster when CD sales kept increasing annually.
I guess we just need to keep trying on this. If America's Test Kitchen can release every episode of a given season (coupled with a cookbook, no less!) for $22.95, we know that releasing entire seasons of BBQ U can work out well too.
(Says the guy who's currently watching the "Season 3 and a Half-ish" boxset of Ren & Stimpy right now.... ).