Advice? I think I melted my Morso 1440 (pics)

We were away from the house for a few days, so I figured it was a good time to clean my stove before I fire it back up. It has seemed just a tad sluggish this year.

This is the beginning of the third season with this stove, and it's my first one. At the end of the previous seasons I had always vacuumed it out really good, but I had never actually removed the baffle. Today, I was able to remove the flat iron plate in front of the baffle with no problem, but when I tried to remove the baffle itself, it only lifted up in front maybe a centimeter but wouldn't move forward or out. So I cleaned all around with a vacuum really well and noticed that one part of soot at the back top of the firebox wouldn't come loose. Then I realized that it looks like there is some sort of melted "something" that seems to have "fastened" the back of the baffle to the rear fire brick! See pics.

So I reached in above the baffle to see what I could feel. Definitely some ash buildup at the very back but didn't seem serious. But amongst the ash, I found two steel (I think steel) washers just sitting loose at the back of the baffle. No idea where they could have come from. I pulled those out, vacuumed again, but still couldn't feel anything odd above the baffle. Nevertheless, here I am with that weird melty spot and a baffle that won't come forward, as well as two mystery washers.

Obviously it's time for a professional inspection. But I'm just curious if anyone has any insight as to what happened here? I've never (to my knowledge) overfired the stove, I've never seen any part of it or the connector/pipe glow, and I have a thermometer and always turn down the air if it looks like it's getting too hot. What did I do wrong?? And where the heck did those washers come from???

Ya know I looked at that exact diagram before I posted this question but completely missed that! I was looking only at the baffle pieces and didn't notice the tube on the rear piece.

So I guess now the only concern is where those two washers came from and if my stove is one light breeze from falling apart.

begreen said:

I don't know this stove well, but the recess in the baffle looks gasketed and intentional. I'm wondering if this is where the secondary air tube enters the baffle? If so the baffle would have to be lifted up over the tube before it could be pulled out. At least that is the way it is in PE stoves. I'd ask your Morso dealer for some info here.

EDIT: Looks like that is the secondary air tube based on the parts diagram.

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I'm guessing "Part 53" is the washers I found. What exactly is an "air slider" washer??

Anyone know what an "Air Slider Washer" is?

begreen said:

According to the diagram it's a washer under the set screw on the air control's slider valve.

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I'm really lost here. I don't know what the "air control's slider valve" would be on this stove. I only have one air control, which is a knob on the door. The secondary air cannot be adjusted on my stove. Anyone have any idea what happens if I try to fire the stove without those washers?

begreen said:

Why are you assuming the stove is operating without those washers? The washers you found could be anything including an extra pair that slipped in the manifold assembly process and were replace with new ones rather than taking it apart.

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Because I'd rather assume the worst and be wrong, than assume the best and use an unsafe stove.

I have an appointment with my local Morso dealer for an inspection but it isn't until after the New Year which is why I was seeking advice here.

Thanks

Thanks a ton, Squirrel!

Yes I was leaning toward the washers being from the draft reducer somehow, but it seems to be in place just fine so I'm not worrying too much.