Here is a slide show of the process photo 1 the red Encore loaded into the truck
2 installled
3 the old encore being unloaded from the truck and the rest of the older stove which will be rebuilt
This stove has seen 20 years of use the owner never used the. Cat bipass the compartment was full of ash
This model stove one removes the real plate (4 phillips head screws) for complete acces to the cat combustor
the floor grate is bowed and cracked into a c shape both andirons are gone the damper bi pass frame is warped and useless it needs replacing
the top back inter part of the stove where the entrance to the combustor compartment that casting needs to be replaced.
I placed the air compressor hose in the stove and exposed every gasket needing to be replaced including leakage out the griddle the front doors the glass gaskets of the front doors
tha ash pan gasket gone and the door does not shut tight this will be corrected with new gaskets and adjustment of the latch Thee air compressor sets off the ask into a cloud and it also exposed leakage around the top casting. the good news no outer castings are warped or damaged. More good news the ceramic insulated cat combustor compartment is completely in tact
A very expensive item that will not need replacement the original cat may be ok no break down of the ceramic ellements though it should be boiled in equar parte water and vinegar for 10 minutes to see if it remains intact and a total cleaning If it remains in tact I may be ok to use Hard to say it appears to have been never used and years of fly ash actually protected the combustio and ceramic insulated compartment. I have offered this to Goose so that he replaces his smoke dragon he needs rear exit venting and the Encore matches his height restrictions.
He will have to convert the 8" oval to 6" round collar flange sold as an option but tested and approved for 6" opperations. No this stove is not a walk in the park rebuild but the price is right that should make it worth while. Goose if you think either the expense for replacement parts or the amount of work too much let me know.
The other thing this stove was tested and approved to the state of Oregon standards What this means is the state of Oregon had passed simmilar standards a few years before the 1990 EPA standards for all practical comparisons they are the same this stove can be considered EPA phase I compliant Especially if rebuilt witha new cat combustor It can run just as effecient or very close to even modern day stoves surpassing even many new ones today
the slide show link
http://s108.photobucket.com/albums/n10/elkimmeg/donor stove/?action=view¤t=833e0051.pbw