Need advice about an PE Alderlea T5 and the baffle key

[BirthofSerpents]

Real straightforward: the hole for the baffle key in the secondary tube has never aligned correctly with the tab for the baffle. Overtime, it's just gotten worse. It's making what should be a 10 second process into a very long, onerous process I dread. I've included pic below for illustration.

Question: can i just drill the hole out a tiny bit larger (1/8 - 1/4") to make the key easy to insert so maintenance isn't such a PITA? My concern is stove performance and letting extra air in. Alternately, I know when my baffle is correctly installed. Can I just leave it open and not use the damn key.

 

[begreen]

Before doing anything, make sure that there is nothing causing misalignment like crud on the side rails or trapped insulation blanket. If anything gets changed, file out the baffle tab, not the hole in the manifold tube.

 

[BirthofSerpents]

Before doing anything, make sure that there is nothing causing misalignment like crud on the side rails or trapped insulation blanket. If anything gets changed, file out the baffle tab, not the hole in the manifold tube.

That makes sense. I was looking at this backwards.

 

[bcrtops]

Mine always looks the same.....a little jiggling always manages to get it in.

 

[begreen]

I use a Philips screwdriver to align the holes prior to inserting the pin.