50% closed to 0% closed are basically the same thing for when the stove is hot. So when I do a hot reload and set the air lever to the halfway point, thinking I'm getting some air in, I'm basically setting the air to 0% causing less primary burn and more smoking with the bypass closed. I don't want the flapper fully open, I want the flapper half closed so I still get some decent primary burn but not too much. And I don't want the flapper closed because then I'm not getting enough primary burn and too much smoking which eventually leads to my cat skyrocketing. At this point I understand even with the flapper closed there is still primary air coming in through in the EPA hole.
In the other thread I mentioned how running the stove hotter has been giving me better burns and it has been more manageable. This is what made me look at the flapper and really see what the position of the flapper was is correlation to the lever travel. This is when I found that when the stove is hot, the lever in the 75% position actually has the flapper about half closed, and lever at 50% position (pointing straight down) has the flapper fully closed or just barely cracked open.
So yesterday I ran my stove with this in mind. Since I started burning, my glass goes black if the air setting is at 50%. The way I have run it up to this point is get my stove up to temp, close the bypass, get the cat up to my operating temp, and cut the air to 50%. Again, unless I'm missing something, when I thought I was closing the air down 'some', I was actually closing it all the way down. If there was enough good primary burn before this point, I shut the air down to 0%, causing much less primary burn, now making more smoke, and higher cat temps on the back end.
I ran using my "new" 50% and had no black glass, just a light haze. My cat stayed well within range and my STT's were more responsive to my air lever adjustments. It was doing what I wanted it to do and what I have been expecting it to do. This is all based on a hot stove that's been running and been up to temp for awhile. How would this differ from a cold start? I would assume the flapper position would be more align with the lever position. So from a cold start I, again, would assume it not being the same.