Pagey said:I definitely would not burn until I had a professional inspection. Though you say the fire was outside the liner, I find it interesting that you had a quart of black, crispy creosote fall into the stove, thus suggesting it had to come from INSIDE the liner. Is it possible that the fire actually began in the liner and got the liner so hot that the exterior of the liner caught up what was left in the masonry flue?
I agree
Is there no top block off plate? I would think if there was a fire in the original chimney the smoke and fire would have no escape ( if you had a plate and you should ) and you would have more than some smoke in your house in fact you might not have a house. When I had my insert put in I had a sweep come in and clean the old clay chimney with one of those big cable whip cleaners. When he was done he said it was normal for a little creosote to fall down around the stove as the small amount that was left dried out and I should check and clean around my stove periodically. After 2 years nothing although the first year there was some. I think your fire was in your liner, and on a side note you can easily build up enough creosote for a big chimney fire in a month or 2 not fully seasoned wood and closed damper for long burns = creosote.