If you don't like long, drawn-out stories, then you might want to skip this post...
Here's an update to the inside smoke smell coming from my Sirocco 2.0, which is at its worst when filled with wood and then subsequently dampered down for the long burn.
Replacing the Duravent stovetop adapter with the Amerivent adapter (and removing a small blob of welding material at the top/inside of the stovetop collar) reduced the smell of smoke in the room by a lot. Previously when investigating this issue, I could get a clear whiff of acrid smoke just above the stovetop collar. That smell above the collar was completely eliminated after installing the Amerivent adapter.
Next I had a look at the stove door, after doing a test burn to check the results of the new adapter.
Highbeam's butthole theory on smelly stove doors appears to be a dead dog, in this case.
In sniffing the stove door at the hinge side with a cold stove, no smoke smell. In sniffing the same spot with a full load of wood burning hot on high damper, no smoke smell. However, after dampering it down for the long burn, there was a distinct smell of smoke from the hinge side of the door, and to a lesser extent along the length of the door, which means the seal/gasket on the stove door is definitely passing some gas. And it would appear that I have a sensitive smeller.
The next time the stove cooled, I inspected the door gasket closely. It looked good, with the gasket well aligned with the steel on the door opening, and a tight fit when closing the door (with the tight feel beginning before the door fully shuts, when it first engages the gasket on the hinge side). Not wanting to disturb a good looking gasket, I had the bright idea to run a thin bead of Meeco's Gasketing Cement and Stove Sealer along the juncture of gasket and the stove door, on the inside at the hinge end (some folks suggested smoke was finding a path under the gasket on the hinge side, where there are some bolts...). And yes, I kneaded the tube well before application. I was feeling pretty good about things, and fired up the stove. After it was going full throttle, I noticed that the black Meeco's had turned an amber brown, and was bubbling up along the gasket like sap does from a crack in a burning log – it is possible that I didn't let it cure the full one hour, can't remember for sure. The smoke smell from the door hinge returned in full force. After cool down, I inspected the gasket, and the Meeco's was a long blob of brittle foam-like material where I ran the bead.
At this point, I would have liked to pick up the stove and throw it out the front door, but thankfully I am not that strong…
I had to make the two hour round trip to the nearest town from my mountain retreat in Northern California, so I picked up a tube of Rutland black high temp silicon sealant. I would have picked up a new stove gasket, but the hardware store stocked absolutely every size of Rutland gasket except the 7/8” called for in the BK Sirocco owner's manual. I contemplated just pulling up the gasket at the hinge end of the door, and pumping some silicon sealant under it, but the instructions say there's a 24 hour cure time, and meanwhile I am trying to get over a cold and there's a winter storm watch for tomorrow evening.
Somewhere in the middle of messing around with the stove door gasket, I added a 2' section of chimney to the existing 15' stack (including two offset elbows), for a total of 17'. (The BK Sirocco 2.0 owner's manual really should mention adding 1' of stack for every elbow. It would save some hassle, and might influence where and how people decide to install their stoves). Adding 2' to the stack may have helped the fire start a little faster, seemed to liven it up on hot burns, and may have helped just a little to extend the time the cat is active on long burns, but did nothing to help resolve the smoke smell issue coming from the door gasket.
At this point in time, my sweet young Sirocco 2.0 still stinks. I am contemplating the 4 hour round trip to buy a new rutland gasket from the supply store in Medford, Oregon, or ordering one online during the busy Christmas season, but it is really getting a bit frustrating, messing around with a brand new stove. I am starting to believe the smoke smell coming from the BK door gasket must be a known design issue, perhaps related to those long burn times that BK stoves are known for, that arises when the gasket is not aligned and cemented with perfection.
Attached is a picture of the inside of the door gasket at the hinge end. It looks a little funny due to the Meeko's that I put on and then scraped off, but the fit is good and there is little to no indication of where it might be leaking.
Pity the old lady with a Chihuahua on her lap, who just wants to enjoy her new BK stove.