Home made refractory package for Resolute

[Brian VT]

I spent $80, but now that I have my measurements, etc., I think I could build it with less waste and
maybe get the board cheaper on Ebay ? I also wonder if there's a stronger material that could be used.

 

[dougand3]

Great job, Brian. Would love your measurements - it may fit exactly in my VC RA 0041. Thanks, Doug. PM sent.

 

[Brian VT]

Update:
Been burning, pretty much, 24/7 for 3 1/2 months. Still good so far.
The other day I noticed some "potato chips" on the shelf above the lower holes. That made me wonder if the Kaowool box was deteriorating.
Luckily, we are having a heatwave. It was 40F today and it's supposed to stay above freezing for a few days.
Perfect opportunity to shut down, clean the chimney, and check the Kbox.
I removed the stove pipe, firebrick, metal side plates, and was planning to remove the upper fireback and remove the Kbox.
Before removing the fireback, I stuck my fingers anywhere I could into the Kbox. It seemed just as new, except for a couple small
"potato chips" that popped off. I'm not sure what's causing the small layers to crisp and separate but it's very minimal and is not
a concern to me at all right now. 98% of the Kaowool board feels like new. I feel confident it will be in good shape after a full season.
I'll keep you informed.
As for giving measurements/instructions...I'm paranoid of the blood-sucking lawyers in this crazy world more than I am of a house fire.
I do not suggest that anyone try this experiment and I won't to offer help in doing so because, if something happened, too many
people want to find someone else responsible. I'm sorry. I hate to be like that but that type of crap happens daily.
The testing/approval process and liability insurance that the maker of the OEM box must have to go through is probably the reason it costs $225.
Otherwise, they might could be selling them for $50 and still making a decent profit.

 

[ControlFreak]

Here's the final product before it goes in. Let's hope for the best.
You can see the upper and lower air holes a bit better in this pic. The lower air holes are cut/stepped back into the box, like the OEM.
The bottom front got shaved for the upslope of the cast iron floor it sits on.
I don't know if I'll fire it today. It's almost 60F. Plus, I plan to head back into my tree stand later in hopes of putting some deer meat in the freezer.

Wow, this is one of the best threads I've seen yet. Where does one typically get the Kaowool?

 

[Brian VT]

Wow, this is one of the best threads I've seen yet. Where does one typically get the Kaowool?

I got it at a plumbing supply house (F.W. Webb). I've seen it online, too.
This is my 2nd year running this box. It's been running 24/7 since Halloween, except for 1 warm week we had.
The stove is still running great. Very predictable and easy to keep a routine. Rake the coals, load it to the top. Repeat 8 hrs. later.
I haven't been finding any more "potato chip" pieces of the box. Maybe that was just when it was "breaking in" ?
I don't know what it's present condition is, but I will tear the stove down in the off-season and will post a report here.
(I know. I said that last year. LOL)
I had the pipe off @ Christmas. The top of the box felt as new.
I also stuck my fingers up into the "channels". Felt ok. They are still there, anyway.

 

[begreen]

Have you had any issues with logs banging up against it, especially when top loading?

 

[summit]

that is great!

 

[Brian VT]

Have you had any issues with logs banging up against it, especially when top loading?

?????
Can't happen. It resides behind firebricks. If you try, you could jab the bottom of it with a poker.

 

[begreen]

Got it. I haven't been in a Resolute since the early 90s. It's great to hear this is working out well. I have a friend that finally gave up rebuilding her Acclaim due the repeated costs.

 

[Brian VT]

I thought I'd post an update.
I ran it for 2 years and it held up pretty well. I would check it the best I could when cleaning the chimney and
I'd stick my fingers up into the baffles (gently) whenever we got a warm spell and I let the fire go out. All seemed fine last time I checked it (March ?).
I'm going through the stove today in prep. for the coming winter. I just pulled the box out and it will need some attention. Not bad, though.
The main box, which is made of 1" thick Kaowool, is perfectly fine. The face and baffles, which were 1/2" thick Kaowool, are toast.
I think another small sheet for the repair will cost @ $20, so I'll be up to @ $100 and expect to get at least another 2 years out of it.

Edit: The 1/2" stuff seems to be the weak point. Maybe I should try 3/4" or 1" for the baffles and face ? Too restrictive ?
I'm also wondering how important the baffles are and what purpose they serve. Maybe I should just put a 1" face and no baffles ?

 

[Brian VT]

Well, the only sheet they had in stock was 3/4"x20"x30", twice as much as I need and it was almost $50.
So...the baffles and face are 3/4" thick this time. Maybe I'll get 3 years out of them and then I'll have replacement material on hand,
if I can remember where I put it.
I suppose the whole box could be made from 3/4". The bottom would end up being 2 1/4" thick (3 pcs.) to allow for that long row of holes.
Warm wishes to all for an enjoyable winter.

 

[Redbear86]

Not that i don't care about emissions.... but i wonder how much of this is for achieving a secondary burn compared to achieving their 3.4 g /hr epa test?