Hello nick01,
First do some measuring to determine the depth of the hole avaible to install a new zero-clearance EPA fireplace. Pretend that you just ripped that inefficient builder box fireplace out of there. What is the depth of the hole (from the front surface (your wall) to the framing behind the fireplace).
Here are some zero-clearance, high efficiency (EPA certified) fireplaces you should consider:
(Note: Lennox own Security Chimneys (BIS fireplaces))
Lennox Villa Vista (sames as BIS Panorama) This is a CAT (catalytic) unit.
Lennox Brentwood (same as BIS Ultima)
Lennox Solana (more basic unit, less expensive)
Lennox Ladera - same as BIS Nova (more basic unit, less expensive)
BIS Tradition (not sure if there is a corresponding Lennox branded unit)
BIS Tradition CE (not sure if there is a corresponding Lennox branded unit)
BIS Ultra (not sure if there is a corresponding Lennox branded unit)
Kozy Heat Z42
Osburn Stratford
Napoleon NZ26
Quadrafire 7100 - same as the Heat & Glo Northstar
Fireplace Extrordinair 36 or 44 Elite. These are CAT units.
Supreme Zero Clearance (
www.supremem.com)
RSF Opel 2, 3, Delta 2, Topaz, Onyx 2, Oracle (see through unit) fireplaces
I was in the same situation as you. After ripping out my old piece of crap Majestic builder box fireplace I had a 24 inch deep hole in which to install a Zero clearance EPA fireplace. I then eliminated all fireplaces deeper than 24" from the above list. I wanted a fireplace with a firebox larger than 2.0 cubic feet because I feel 2.0 cubic foot or smaller firebox is too small. So I eliminated all fireplaces with 2.0 cubic foot or smaller fireboxes from the above list.
Ultimately I ended up with the Osburn Stratford. It has a 2.5 cubic foot firebox. I really like it & it worked out great.
You should also consider the KozyHeat Z42 if you can accomodate its greater depth than the Osburn.
Both the Osburn Stratford and KozyHeat Z42 are reasonably priced & good quality. They represent good value in my opinion.
The Quadrafire 7100 (Northstar) & Fireplace Xtronodinairs appear to be good quality but are quite expensive. They will blow your $5000 budget.
Your actual choices of zero clearance, EPA fireplaces will depend on what your local Hearth dealers carry or how far you want to drive.
Plan on having to replace your chimney. I highly doubt your existing chimney pipe will be compatible with the type required for an high efficiency EPA certified fireplace. . Most builder box fireplaces use 10 inch chimney pipe due to their inefficiency - they need big pipe to transport all that heat outdoors! My builder box fireplace chimney was 10 inch. I had to replace it with 6" of the type recommended by Osburn for the Osburn Stratford fireplace. You MUST use the chimney pipe model as recommended by the manfacturer of the fireplace.
Good luck!