When the guy from the shop came by I was told he ran rods up the chimney and they came out clean and even commented on how clean the chimney was. But I'm guessing that they didn't get up on the roof and look at the cap. Currently with the bypass open and thermostat wide open I'm barely getting anything but a glow from the firebox and no smoke coming out of the chimney.Birds nest, bee hive, squirrel nest, dead bird or something in the flue perhaps?
Or that bypass door you said seems not quite right? Maybe a gasket loose or something is out of alignment?