I would also look at the Jotul F500. It's a more reliable stove unless they have changed the secondary rack design on the 118CB.
The 118CB appears to put out less heat than the 2460, at least according to the EPA test figures, which I know must be taken with a grain of salt. Jotul claims it will heat 2000 sq.ft. Majestic claims 1400 sq.ft. for the 2460. Mfgr. claims are to be taken with a grain of salt as well. (broken link removed to http://www.epa.gov/oecaerth/resources/publications/monitoring/caa/woodstoves/certifiedwood.pdf)
We've done gaskets once and the converter twice in the 5 years we've been burning the dw. We burn a lot of ash, hardly any oak. A lot of it is dead in our woods, if not it's been seasoned as long as possible. Put in a big pile, then split & stacked in a small open garage when dry. If my husband wasn't so busy farming I would get him on here. He knows better than I do what we've burned.
We aren't opposed to new just trying to save $$. We really like the look of the jotul 118 cb. Need to call around to find out retail.
Just looked at thread on here about the 118CB...was apparently $1500 several years ago. From what you've said, I agree with Grisu; Wet wood is most likely your problem with the Dw, and will be with
any stove. The best way to tell for sure is to get a cheap moisture meter at Harbor Freight, Lowe's etc, re-split a bunch of splits you have stacked, and test on the fresh surface. You will then know about your wood, without a doubt. Anything at 20% or below will burn OK. I like mine below 18%. As I mentioned, you can probably find
small, dead trees with the bark gone that may be ready to burn well right now; Mulberry, Sassafras, Red Elm,
maybe Dogwood, down Black Locust, etc. May be hard to do, with farm chores to attend to. You seem to want to go to a non-cat but at the same time you want to save money. That's why I've continued to blather on about the Dw, it would be the cheapest way to go (provided it's big enough to do the job, and your fuel is dry.) What did your combustors look like when they were shot? Cracked and crumbled? Scooped out spots? Did you replace the cat probe thermometer as well? On the 2460, I run in bypass until the cat probe gets to around 500, then close the bypass. If the cat is working, the probe should then climb up to about 1200. You can also look up through the glass and baffle, and see the cat glowing early in the burn. When I reload, I will also run in bypass to establish the new load. If you toss wet wood in and close the bypass immediately, they say that can thermally shock the cat and result in damage. Those cats should be lasting five or six years. If you are going to spring for a new stove, maybe a non-cat will do a little better with wood that isn't dry enough, I don't know. begreen and Grisu are two of the most knowledgeable members here, and have made some good stove suggestions. More details on the size and layout of the home, and stove placement, will help narrow down the choices.