smoke spillage

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IDK how it warped but looks like you found your smoking culprit.
 
isn't that the air wash?
That's odd; that'll be the most cool piece of the stove...
More likely mechanically bent than warped by heat imo.
That will never glow (imo).
 
Yeah changed airflow from the distortion could be part of the problem.
Tough to say for sure as i'd still lean towards wet wood as at least a possible partial factor.

Wood and the bent plate seem to be the 2 most obvious sources of change from previous burn years. Also as stated before more burns due to colder season this year could have added to the problem.
 
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isn't that the air wash?
That's odd; that'll be the most cool piece of the stove...
Yes, according to Englander tech support, that's the air wash. But it would only be relatively cool when the damper is open. It could possibly have overfired and warped when I was asleep with the damper closed.
 
Question: Are some stoves more or less likely to be damaged by overfiring than others?
Yes typically the cheaper the stove the less durable it will be. Not always true but it's a good general rule. For example the part that is warped on your stove looks like a heat deflector to protect the air wash manifold. On Regency stoves that part is now bolted in instead of welded one so it can expand and contract more and two so it is easily replaced