First, I'm not an active poster on this site, although it has been a wealth of information over the years and helped me decide on the purchase of a gasification boiler. Thank you to everyone who has posted helpful information over the years on how to operate and maintain these units. I have an Econoburn EBW-200 model that I purchased new in 2008 and it has been in use for every heating season since then. I'm in central New York so our heating season generally starts in October and goes into March-April. I've been very pleased with the performance of this boiler over the years since it has been very reliable with minimal maintenance. Besides the yearly turbulator cleanings, I've replaced the fan capacitor, door gaskets and ceramic nozzle once. After replacing the nozzle, I cut a plate of 1/2" thick steel with a slot in it to fit over the nozzle to protect it, and it has worked well to reduce the wear to the nozzle and doesn't seem to have any effect on the gasification process. When I initially purchased the boiler, I had intentions of eventually adding 1000 gallons of pressurized storage. After using the boiler for a couple of seasons without storage, I realized that I was satisfied with it's performance, and decided against adding storage. Fast forward to a couple days ago, I came home from work to find the fire was completely out and the ash was a soggy mess inside the boiler. After shutting down the water feed and cleaning out the boiler, I found a small hole in the front wall inside the upper chamber, about halfway between the bottom of the door opening and the floor. Further inspection revealed the front wall is paper thin in the middle since I could easily poke through it with a screwdriver. The steel feels thicker when I tap on it as I work my way outward from the center. The front wall is clean with little to no creosote buildup. The steel appears to be slightly wavy as if it is warped from the heat. All of the rest of the walls are structurally sound with a thin coating of creosote buildup. When I scrape off the creosote coating, which is like a thin coating of tar, the steel underneath is shiny, clean looking steel, with no signs of corrosion. The boiler water I drained out was nice and clean, with no signs of rust or corrosion debris in the water. I called Econoburn and was told the issue is likely due to corrosion from creosote. In my opinion, if the issue was creosote related, then all of the walls would be suffering from corrosion. Rather, it appears the thin creosote layer actually protects the bare steel from corrosion. I didn't ask about warranty, even though Econoburn advertises a 25 year warranty on the pressure vessel. It's a prorated warranty and after 14 years I'm in the lowest bracket where they would only cover 20% of the cost of the repair. I'm about 4 hours away from the factory (about $100 round trip with current diesel prices), so I decided to call a local welding company and they're going to come out tomorrow and assess the situation and hopefully be able to weld a patch on the inside of the front wall. My brother has a smaller size Econoburn put into service around the same time, and he hasn't seen any issues with the front wall deteriorating. I'm curious if anyone else has seen had these issues? I'm not upset with Econoburn since I think they build a great boiler which has given me 14 years of trouble-free service. I'm definitely money ahead than if I were to have heated with propane for 14 years. I was just expecting this boiler to last 20+ years. Even if it is patched up successfully, I realize this is a bit of a bandaid fix and it will always be in the back of my mind that it will eventually fail again, in the middle of winter. I'll try to get a pic to attach to this post when I get home from work.