Installing Rope Seal (1” round rope)
Re-position the wood boiler door hinge and latch as far out as possible and install 1” round rope seal with a ½” bead of high temperature caulk behind it to glue the rope in place. Use a thicker layer of caulk where needed to push rope out for maximum adjustment. This method can accommodate up to a ½” of misalignment. Make sure to push the rope to the outside of the corners to mate properly with the jamb (do not stretch the rope). Put some caulk on the joint ends after cutting the rope and make sure the ends are compressed or smoke will seep through. Over-extend the door latch open and bounce the door closed twice to custom fit the seal to the jamb. If there are thick spots of caulk keeping the rope pushed out, leave door open 24 hours until caulk behind rope is fully cured. Re-adjust door to properly seal.
Pre-condition rope as explained below. Start the boiler and tighten further if needed.
Pre-conditioning Rope Seals
Option 1: (Good) Wet the rope seals with WD-40 before firing the boiler to keep prevent hardening from smoke and creosote and re-apply 1 or 2 times during the heating season or as needed.
Option 2: (Better) Purchase a tube of high temperature caulk from Randy and lay a bead of caulk on the impression of the door jamb in the rope seals, placing a 2” strip of wax paper over them.
Over-extend the latch open and bounce the door/ash pan closed, then leave open to fully cure before starting a fire to get a custom seal. Once cured, wet the rope seals with WD-40 to prevent hardening from smoke and creosote and re-apply 1 or 2 times throughout the heating season or as needed.
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Option 3: (Best but more hassle and messy) Purchase a tube of high temperature caulk from Randy and brush over the entire surface area of the rope seals to permanently seal out smoke and creosote. Place a 2” strip of wax paper over this. Over-extend the latch open and bounce the door/ash pan closed, then leave open to fully cure before starting a fire to get a custom, long term seal.
NOTE! Adjust fuel door if you ever see any amount of smoke.
Door adjustment is done at the factory but may be required again after installation and before starting a fire as the seals compress over time.