Do Pellet Stove Gaskets Wear Out On The Door?

Take a strip of paper or dollar bill and close the door then pull the paper. If it gives sine resistance while coming out, should be good. Check various spots around the door. Sounds like it's time though.

I would start looking very hard at a exhaust leak! I have seen holes in that stoves exhaust fan housing too. So many areas to leak in the exhaust system.

Did you at any time bypass the vacuum switch?

Fsappo said:

Did you at any time bypass the vacuum switch?

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There is no vac switch on that stove. Scary ain't it, and they still sell em

I think the babys and the T40s had vacuum switches. Not sure what exact model the OP has, unless I missed something.

Baby was introduced I think around or just after 04

Makes sense, that is about when I started selling that brand

The fire box is at negative pressure and, once the fire is going and the door is closed, it should not be possible to leak smoke out of the fire box. Leaks at the door seals or other seals on the fire box are to prevent air from entering the fire box and bypassing the fire pot. If the flame is active it unlikely that you have a significant leak there. If the vent and blower path is compromised (in need of cleaning) or if the blower is not functioning properly it is possible for smoke to leak from the fire box because the negative pressure is not adequate. You would know that is the problem because the flame would be lazy and possible sooty.
The path from the combustion blower out to the vent is at positive pressure so that is where you should be looking for leaks. The worst culprits, when it comes to leaks, appear to be elbows and cleanout T's.

Just replaced the tadpole gasket on the door of my 6-year-old Santa Fe, and it eliminated a smoke leak. The leak wasn't when the fire was going well, but when it was being ignited. As the pellets are catching the stove fills with smoke for a moment. Some of that was getting out. Not enough to see but enough to smell, and be slightly irritating. There's also a more effective air wash for the glass with the new gasket.

Change it. It's past due.