Hmmm. My Ashford spills ashes behind the pan too but although I prefer to shovel once my wife might prefer the ash drawer when I am absent. Do you go through the stove store or BK directly?
Well, given the design of this pan, it's possible your ash spillage has nothing to do with this issue. Bottom line, if you put too much in the pan, the top of the frame will strike off the excess as you withdraw the pan, and leave ashes on the floor. That's just typical of any stove with a pan in a drawer.
This issue of the mismatched pan frame is specifically those few stoves that were made with the pan too far forward for the plug location. Like I said before, the plug would be literally flush (zero point zero inches) with the rear wall of the pan.
As to your question, you can message BKVP thru this forum, and he'll give you an answer on this.
You made it sound like the refit wasn't to hard.
In my case, it ended up being very easy, but you may not be quite as lucky. The pan frame fits snugly between the four legs, and given manufacturing tolerances, it's likely you might have to loosen the leg bolts to permit enough slop to get the old pan frame out and the new one in. In fact, their procedure calls for this, jacking up the stove, supporting it on cribbing, and removing the front legs. In my case, I found the new frames were so dead-on matched to the old frames that I was able to do the swap without having to lift the stove or loosen the legs.
Basic procedure was to lift off the top, loosen a few bolts holding the sides on, lift them off, and then you have access to the pan frame mounting hardware. Drop old pan frame, swap cast front lip to new pan frame, install, and then re-hang sides and top. Took me less than 30 minutes per stove.
Note 1: Their procedure says you only need to loosen the top two hanger bolts on the side castings, the lower ones should be loose enough to just lift off. However, three of the four lower rear bolts were snugged between my two stoves, and had to be loosened before the side castings would come off. Be sure to not go tugging and prying, before checking them, you don't want to snap a casting. You'll need a thin open end (7/16") wrench, to get at them.
Note 2: Remember to remove your pan lid from the bottom of the drawer in the old frame before throwing it in the garbage, I forgot one of mine, and now it's gone! I can't say I used it very often, but it was a nice thing to have, on certain occasions.
