finally new stove installed BUT door isn't flush - do I return?

Some may remember my previous post on my difficulty getting a liner and honest man to do the job. I settled eventually on a lopi republic 1750 stove insert and had it installed w/ 6" liner and insulated the chimney it's going up through with the loose lava rock/vermiculite.

Anyhow, the stove works great but the huge disappointment is the door does not sit flush. the bottom left corner below the handle to open the door constantly gets black build up when I'm burning even couple hour fires. With overnight I notice even still that that corner has by far the heaviest build up.

I understand the technicalities of wet wood, and wood placement and oxygen control that factor into dirtying the glass. But the way that it constantly builds up in this corner, and the fact that I can look at the door and see that it clamps tightly shut on the top and other edges but bends out slightly at this bottom left corner (putting less pressure on the gasket) has me thinking it's faulty.

I did the dollar bill test - everywhere I put the bill it is very firm, except there. When I put it in that corner, with some effort I can wiggle it, and it does slide out more easily at this spot than anywhere else as well. It doesn't wriggle freely or fly out when I tug, but it is noticeably easier to wriggle and pull than elsewhere around the door.

The door seems fine, the hinges seem to be the problem - I can take out a bolt and then position the door to where it will clamp flush all the way around. The way this stove is constructed, the hinges are welded, and not replaceable or 'tweak-able'.

So I am faced with returning this stove for a new one without defect (under warranty), which is a big pain but really I think is what it comes down to unfortunately. I could try messing with the spacers, but I hate to think that this massive investment is faulty and eventually as the gasket wears down it will be even more of a problem and pain to constantly have to cater to.

Wondering what thoughts all of you here have on this situation. Does the dollar bill test and other signs indicate it's worth considering replacing?

Or is it all coincidence and the buildup is simply normal to happen on that edge, especially since that would seem to be the spot of coldest air to hit when opening the door to load more wood once in awhile?

Thanks for all your thoughts.

heres a pic too, you can see how it bends out:

I think yes the first step they would do as a manufacturer would be the door. It seems to be a hinge issue, but perhaps the hook going into the hinge (that's on the door) could be the issue. The thing is when I take the hook out of the hinge and close the door, it sits flush. So the problems lies in how its fitting into the hinge, or the hinge itself is slightly crooked.

I did have a rep out this morning who did admit to the fact its not an even fit. I will have a closer look at the gasket and see, but it doesn't seem to be the issue, because of how it closes flush when I disengage the door from the hinge.

Basically wondering...is it all coincidence and the buildup is simply normal to happen on that edge (b/c of opening the door?), especially since that would seem to be the spot of coldest air to hit when opening the door to load more wood once in awhile?

If not...then I might have to replace the entire stove unfortunately...

any thoughts greatly appreciated.

Carbon_Liberator said:

Could be just uneven gasket too, as has been suggested
I had a look at mine and I notice mine has a much thicker gasket.
Here's a pic

Click to expand...

Thanks for sharing that pic, thats interesting. Our gasket is a bit different - I did take the pic with it shut so that might account for some difference, but having a look at the gasket some of it seems bulky near the hinges and thin near the door clamp - don't know if this is the cause of, or result of the uneven fit. Going to bang away at the hinge tomorrow - try to manipulate it just a bit, if the fits still bad, will be in touch with the dealer for a new door I think. I really hope the situation can be resolved with either of those - I don't want to go through installing a new stove again.