Hello Everyone! I made the jump and bought an Osburn 2400 a few years back when the big tax credit was still available. After some shipment issues (due to damage), I installed the insert in February 2011. Background: I installed a block off plate in my masonry fireplace. I cut a piece of galvanized metal (Purchased from Lowes) and sealed around it using 3M Fireblock Sealant from Lowes. The part number is FB136 and it says it is for "chimney and fireplace" among other things. I installed a brand new 6" stainless liner in my 13"x 13" clay flue. I cured the paint on the Osburn as instructed and began using the stove. It worked great and heated well but put out a strong odor once it was heated up and cruising. I used it for a few months during the cold nights of February and March and had the firebox packed full on several occasions leading to a hot fire. I shut it down in the spring of 2011. In the winter of 2011/2012 it was so abnormally warm that we didn't use the stove much so we didn't have to deal with the odor. I cleaned the flue a few weeks ago in order to get ready for burning season and started our first fire of the year a few nights ago. When I did, I noticed the odor again as soon as the stove was heated up. I cannot smell anything until it is heated up. When it is cool, heating up after initial startup, or burning at a lower temp of 350 or so (when we get up in the morning) it does not smell. The smell is hard to pin down but it does not smell like a chemical smell or paint cure smell. It smells more like a hot clutch or brake smell from a car or 18 wheeler. I have read people say that it may be reaching temps that it has not reached before and may be further curing but I know i have reached some high temps with this thing so there shouldn't be any more curing occurring. Any suggestions? Could it be the galvanized metal or 3M fireblock? Thanks!