Broke my Second Glass Installing Door Rope Gasket

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BARTSFAM

Member
Hearth Supporter
Jan 21, 2009
102
Central MA
I'm kind of venting and looking for advice or opinions.
I have a Enviro Milan insert. About 6 years ago, I was changing the rope gasket, bought 5/8" as required. Shutting the door for the first time was very hard, so I forced it, figuring it would squish down for a proper fit. Well, I proceeded to crack the entire glass. Bought a new glass and installed it myself.
I thought I misread the gasket requirement and went down to 1/2". The door shut properly, and it worked for the most part, but I never thought it was as tight as it should be, as the dollar bill passed thru on the dollar bill test. I lived with it for 6 years, but I could tell that it did not burn cleanly like it used to. The stove became very picky with what pellets it would burn cleanly.
Last week my burns were very dirty, and the dollar bill slid thru with ease. I double checked the internet, and again everything said the Enviro Milan called for 5/8" gasket.
Remembering what happened last time, I installed the 5/8" gasket, and mushed it down and worked it and worked it. The door closing was tight, but it did close. Started the stove. Had a good clean burn. About 4 hours into it, I look at the glass, and it had a three inch crack from the lower left corner up. Again I cracked the glass installing a gasket.
In my area, a new glass 18.5" X 13.5" was $315. I finally found an OEM door, in Canada, complete with glass and gaskets for $310 US. Unfortunately the shipping is $75. But, all I have to do is pop it on the hinges and I should be good to go.
But, in a couple of years I'll have to change that gasket again, and I dread it. And I'm still not entirely sure what size gasket I should use. If I should try a 5/8" again, or just suffer with the 1/2".
Has anyone else run into this problem?
 
I'm not sure I understand the original breakage. On mine the door gasket and glass gasket have a separation. If I change my door gasket it does not affect the glass gasket.