this sounds scarily familiar... I had a customer in this same position a couple of years ago.... after coming out to her house I noticed the stove had a similar smell to what you describe, so i tested a new model from our inventory to see if it also had an odor, I noticed a definite difference between the two. The customers stove has a smell I couldn't remove by cleaning the firebox, re-painting, etc. (no fumes of gas leaks of any kind btw) , and our model from inventory had no smell at all, and we ran it for days, and had many different people smell check it. So, finally after multiple visits to customers home, and negotiations with hearthstone, I had the unit replaced under warrantee. The unit installed was the same unit that had been tested extensively, and had no odor when it was burning in our shop. However when we installed it at the customers home, she again complained about odors. when the "warrantee'd" ""stinker""" came back in, we tested it at length in our showroom, it never had any kind of odor what-so-ever, so it was sold as a used stove, and was never heard from again i.e., it lived happily ever after.... Because neither stove had any kind of odor outside of the customers home, we assumed the hearth’s tile glue might be to blame, as we discovered the hearth was set with glue vs thinset, and the stoves convective chamber pulls air from the hearth level passively out the top of the stove… Frustrating situation, I tried my best…. If this is you Mrs. E, please say hi to Carl….