Tx for encouragement. Unfortunately I can't keep this up. Up at 5am, again, for the umpteenth time. Fussing with it.
Am switching back to prior stove. Tired of full loads and 5-7 hours burns, our eyes burning pretty much daily, spending more time fussing with this than my older stove that never presented any of these problems. After fussing with this for 2 months and not figuring this out, my next move might have been to tear out and totally redo the OAK. But that irks me when holding a match to the air intake portal at the floor blows it out. Incoming air flow NOT a problem. I ended up taping every possible junction point with heat tape, something one should never ever have to do and looks like amateur hell... still smoke smell into the house when dialed to a proper runtime position. To prevent this, I am burning wood at a rate faster than my old stove. Getting up twice a night just to run the forced air to clear out the house, or open windows, or... sigh. And expending more maintenance in the process than my older stove. In prior stove I had gas bills of $20-$30... for hot water. Now I am 5-7x that. All manual running of the furnace blower to clear the air. That's a lot of fussing, just that.
I mention these last things and will disappear as while I was excited to receive a BKP that was told had 2 total burns in it, hence brand new.. a demo model... while I was exceedingly grateful... my wife is a liver transplant recipient 26 years out, and has incurred 6 total joint replacements.. and her eyes are burning daily (mine too), cannot sleep which can be very hard for her... so maybe I can expend more time and money trying to figure out what is happening, but I can't put her through any more of this. Redoing the OAK which really irks me when I know it is quite functional is the only thing I have not physically retooled, but if I am going to do that... no, I am not going to do that because any more energy is going to be towards removing this unit and going to what worked fine with 0 issues for 15 years. I absolutely dread what I expect will be the amount of creosote that has accumulated so chimney fire has become a huge concern... this after what I saw after 10 days of initial burn and then disassembling everything from floor up, trying to figure out what was wrong. The amount of creosote that had developed really blew me backwards. 10 days into this and I had a larger mess than 2 years of prior stove. I admit I was really skeptical when stove was delivered and having had two burns in it as a demo as I was told, the door glass was caked, like heavy creosoted, and I mean it has never come close to cleaning up no matter what kind of burns I have run, incl standard hotter burns to just clean things out. There is absolutely no way doing everything I know has helped clean these doors. Manually, hot burns, N/S v E/W loads, scraping... yeah, scraping. Something is just not right with this stove.
So instead of expending more energy and promising my wife that I will figure it out, having managed stoves and installs and not the least of which are having cut and hand split a variety types of wood, estimate 500 cords, hence feel I have a pretty functional knowledge of wood... for 40 years... no, I cannot do that to her. It is coming out so I can return to what works. I cannot do that to her, or to me. And will leave the forum as I know this is tiresome for folks here. And I am tired of hearing myself whine. I need to get back to some positive energy instead of fretting and expending now endless amounts of time, elbow grease and now money trying to figure this out. Instead of conservation of time and $$$, this experience has been the opposite.
And after all my sleuthing... it is impossible to have the smoke smell emitting from the left air vent, where a fan kit would force air across the convection plate. It is impossible right? I mean, there is no possible way for smoke to be coming out of either side of this vent which is just a air way which has no access to anything other than it is a tunnel, right? Yet this is where this smell is coming from. Not the right side of the vent, but the left side. Not the back of the stove. Not the flue which has become temporarily tape hell. But the left vent. After all this messing around, I think this stove is cracked... how else could this smoke scent be coming from this one location? How else could smoke enter into this area? But I don't have the whatever to put more time into it. I will check one more time to see if anyone has made it through this crummy missive and suggest a plausible explanation for why this is coming from this specific location, the left side air vent. There is always a trace of smoke smell no matter if there is a hefty startup fire to bring the cat up.. but it becomes prominent when when dialed into a runtime posture.
Tx for any help. Am sure 99% of folks here have good experiences. I just can't do this any more. Stove is coming out while we have a spate of decent weather. OaO.