Astoria/Yankee Bay Exhaust Flange bolts are very loose! RTV also cracked!

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Don2222

Minister of Fire
Hearth Supporter
Feb 1, 2010
9,149
Salem NH
Hello

Does anyone have an issue with smoke coming out of the back flange? It can easily happen after a few years!

The Travis Avalon Astoria and Lopi Yankee Bay both have a heavy 4 inch exhaust flange to connect to 4" pellet pipe. The screws holding this flange are small and became loose after a few years on this 2005 model.

This flange does not go over all four sides of the exhaust blower housing only 2 sides, so extreeme care must be used to assure it is all sealed properly. The Archguard Optima PS1 pellet stove also has the same type of flange! it was worse and had a terrible smoke leakage issue but can be fixed the same way.
Also I recommend heavier stainless steel self cutting screws to hold better so they do not vibrate loose!

Some models have a heat shield that must be removed first, in order to get at the exhaust flange bolts. I use a small socket wrench with a magnetic bit holder to get in there.
See pics of Yankee Bay below:
Before putting the flange back on, it is a good idea to clean off any RTV, wire brush it and give it a coat of High Temp black spray paint for good looks. :)
Click to Enlarge:

Pic 1 - Removing loose exhaust flange was too easy! Srews were loose and RTV was all broken!
Pic 2-4 - Exhaust housing and flange - See top and bottom has no metal overlap
Pic 5 - Adding RTV -- Should be done to both sides, flange and housing
Pic 6 - New heavier SS screws vs old screws
Pic 7 - Cranking in the new screws which fit thru the flange holes but cut the housing hold a little large for a much better hold!
Pic 8 - Checking RTV to assure coverage
Pic 9 - RTV also applied to inner edge over weld to assure no leakage there (See Red Arrows) and around housing where flange is bolted. (See Blue Arrows)
 

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