What temperatures are you running at? What chimney is it hooked to and how tall is it? Have you checked the seal on the door? That stove looks like it has been seriously abused. And honestly it is bad enough that I would not use it in my house. Did you try to have it replaced under warantee? I have a 3100 that is similar age and Burt 24/7 during the heating season in pa. And I have only replaced the deflector once. And the face is not cracked like yours. I also sell them and have only seen one stove as bad as yours. And that guy burnt it wide open all the time.
I don't know what the operating temperature is; only that we use seasoned cordwood and that we run the stove either completely shut down or, at most, 1/2" open (measuring the intake handle) per the instructions. It is hooked up to a continuous stainless steel stovepipe that runs straight up the inside of our masonry chimney. I'm not sure of the chimney height; the stove is on the first floor of a two-story bungalow. The pipe might be about 25 feet from the stove to the pipe's cap, as a guess.
MA is a bit farther north than PA; I'm not sure what the average difference in temperature might be.
I can only report that the insert has operated well, usually about 20 hours a day, seven days a week, 5-6 months a year, running nearly continuously. With the blower running (we are on our second blower motor; the bearings on the first gave out after about 5/6 years), it heats our entire 1100 sq ft two-story bungalow to a comfortable level; the gas only turns on for an hour or two in the very early morning, or in the mid-afternoons, when we are away and the fire has died, in the dead of winter.
I contacted the dealer and Regency, directly, after the first deflector burned through and they said, essentially, "Well, that does happen," but didn't offer any warranty claim; I haven't pursued it further.
The deformity of the front happened within the first year; the stove has been tight and has worked well since we got it, in spite of that. This was also explained by our dealer and Regency as normal wear and tear OR as evidence of abuse.
The manual is written such that any of the defects we have experienced are considered by Regency to be evidence of overfiring, even though I know that the stove has only been used according to the instructions. So, they have worded the manual such that any defects, such as those we experienced, void any warranty obligations on their end.
The stove has not been used with any fuel, in any way, other than outlined in the owner's manual. Despite that, the top/front area burned through and the face cracked.
I don't believe that this was due to overfiring, because I know how we treat the stove. I believe that it is due to our continuous use and Regency failing to adequately protect the top/front area from the heat.
The point of my post is that one can improve a design flaw/shortcoming in the stove by essentially covering the vulnerable top/front area with fire cement. I have the advantage of seeing and using the stove in person (sorry for the crummy photos
...).
I had a relatively unsatisfying time dealing with Regency when the stove was brand new. After that, I never considered applying to them for a warranty claim.
When we bought the unit, the sheet metal surround came, somewhat inexplicably and unapologetically, 1-1/2" taller/wider on the top than on the sides, which made the alignment with our tile surround (which had been laid out to Regency's planning specs for the surround) look terrible.
It took about 15-20 phone calls and and probably about 10 emails just to get a surround that was the dimensions promised in the literature. Regency's position was that, while the literature gave specified dimensions, all information was subject to change, without notice, and that they essentially had no obligations to help. They finally made a "custom" surround that was just the sizes promised.
After that ordeal, I have avoided dealing with Regency for anything other than parts, and that was through our very excellent local dealer.
I understand that as a dealer you may have some financial investment in promoting Regency; I'm not here to demean the brand or make it harder for anyone to sell Regency products. As owners, we feel that in terms of money saved on heat, we've done very well with our insert, as an investment.
I can only offer that we are scrupulous owners. Every year, we have the pipe cleaned at least once (sometimes twice) and the stove inspected. I've replaced gaskets both on the door and glass, which seal well. I have a backup set of gaskets, if needed. As I mention, I've replaced the full set of firebricks and baffles.
It is a relationship with a mechanical device. It is not a perfectly designed or exceedingly well-made object, but it is a very useful one. I think that I have figured out a way to overcome what I've found to be the weakest point in the I3100's setup; the top/front area.
The stove is sound and works better than ever. Regency offers a lot of bang for the buck. With regular maintenance, ours is heading into season 12 or 13 of daily use as our primary heat source; pretty good for a relatively inexpensive sheet metal stove, I think.
With my new, improved, fire-cemented-over-stainless-mesh-deflector area, I expect this unit to last for several more years of daily use. My only hope is to help another Regency owner improve their unit, should they experience the kind of burn through, in that area, that we've seen.
The photos and comments from other Regency owners, earlier in this thread, led me to think that photos of my fix might be helpful. I hope that they are.
I hope that my photos outline the process I followed. I'd be happy to answer any questions from those who care to replicate this improvement.