Dauntless Air Control broken

[WNCStove]

The air control handle on the dauntless has completely lost link with the door controlling the flow of air.

The stove was not over temped and has been treated very gently and it is only 2 years old.

Anyone have this issue before? I can’t find anything in the manual on how the air control lever actually is accessed or repaired.

 

[cneg34]

This appears to be the right thread for this even though the above question was not answered.
My Dauntless was installed 3 years ago and always had a problem moving the lever for primary Air Control, but it operated.
Last winter it seized up, stuck open. Needless to say, I could only run it with a small load of wood.

Today, I removed the bolts on the inside of stove that holds the inner wall of the stove in place, behind which there is a cable mechanism.
The lever was stuck but when I removed the casing, and turned the lever, the item in the picture in my palm dropped to the floor.

The video (go to about 25 seconds) shows the cable action as I open/close the handle on the outside. Video is here:
https://photos.app.goo.gl/vjdH8zinp1UkiDtY7

How is this supposed to work? I assume the cable which is stuck against the outer housing must be re-routed towards the center of the stove,

What is the metal square shaped object that fell when I removed the inner housing to get at this? It is the pic in my hand.
I believe it to be key stock used in some way and when it fell, the outside lever handle would then move again (but not freely given the position of the cable). But it was no longer locked up.

Any explanations or pictures of a "correct one" would be ideal. Thanks

 

[cneg34]

This piece of stock that fell out when I removed the internal cover to the cable assembly that operates the damper door.
Clearly shows a spot-weld joint on the center.
Now I need to determine precisely where it was and re-attach.

This video shows the assembly after re-assembling it such that the cable was not wedged into the channel.
Without the above stop in place, the lever can be pulled too far when opening and that pulls the cable such that it will wedge and then be completely "bound up" and the damper is stuck open. With a hot fire, there's nothing one can do at that point.

I don't see exactly where it would attach, as I don't see the remnants of a broken weld anywhere.
I've asked my dealer for help, this should be something that VC would have documentation on.
I also think it should be covered under warranty. There was no misuse.
The handle was always difficult to operate and I believe it was assembled out of tolerance at the factory.

Here is the video of operation. Help!
https://photos.app.goo.gl/hpVN7gJxWtdVXx4m9

 

[VermontCrapstings]

I know it is not what you are going to want to hear but if you listen it will save you even further headache. Vermont Castings is no longer the company that built the name. Anything built by them recently is going to have issues. This likely won't be your last issue even if you do resolve the problem. Get a more reliable stove.

 

[Woodsplitter67]

This piece of stock that fell out when I removed the internal cover to the cable assembly that operates the damper door.
Clearly shows a spot-weld joint on the center.
Now I need to determine precisely where it was and re-attach.

This video shows the assembly after re-assembling it such that the cable was not wedged into the channel.
Without the above stop in place, the lever can be pulled too far when opening and that pulls the cable such that it will wedge and then be completely "bound up" and the damper is stuck open. With a hot fire, there's nothing one can do at that point.

I don't see exactly where it would attach, as I don't see the remnants of a broken weld anywhere.
I've asked my dealer for help, this should be something that VC would have documentation on.
I also think it should be covered under warranty. There was no misuse.
The handle was always difficult to operate and I believe it was assembled out of tolerance at the factory.

Here is the video of operation. Help!
https://photos.app.goo.gl/hpVN7gJxWtdVXx4m9

That looks like part of the thermostat. You can simply order a new one and install the entire piece instead of trying to fix it

Disregard the above post #4 things happen with every manufacturer.

 

[cneg34]

That looks like part of the thermostat. You can simply order a new one and install the entire piece instead of trying to fix it

Disregard the above post #4 things happen with every manufacturer.

Thank you - that is a helpful response and what makes the forum great. I am going to have to make this stove work one way or the other!

 

[cneg34]

Thank you - that is a helpful response and what makes the forum great. I am going to have to make this stove work one way or the other!

Dealer is going to try to get the part (the whole assembly) under warranty. My stove is 3 years old and now a week out of warranty, but I'd reported this problem a year ago and also a month ago and supplied videos, pics, and asked questions.... So we will see if they hold up to their end (or respond at all). My dealer is not the issue here though at all.

 

[Woodsplitter67]

Hopefully it's comes soon. I did a thread on a rebuilt a couple years ago. Look it up it may have a picture of the thermostat in it

 

[cneg34]

I found your thread but doesn't look like there's pics of the thermostat assembly.

Thread 'Encore 2040 rebuild..'

Aug 28, 2023

So I woke up Saturday morning and I don't know what got into me but at 6am I started to pull apart my stove. By the time my wife woke up there were stove parts all over the place by 9am I was out in the driveway with a wire brush, air compressor and a number of other tools cleaning it up.

I say its a very interesting stove and not as complicated as I thought.

• Woodsplitter67
• Replies: 46
• Forum: Vermont Castings

I did enjoy reading through it though. I've also learned about how this stove operates by disassembling most of it and am less confused on it's operation.

 

[cneg34]

Part shipping to the dealer at the end of the month under warranty.
Not confident it will be the right part but not much I can do....