Been about 14 months and at the beginning of the season (late Nov) nothing looked off when I had the baffles removed. Today I removed the baffles to check the catalyst and check it out. Yay. I'm glad I checked the catalyst because it was caked pretty bad as well. Came right out with a shop vac though. Really just a PSA. I have an email out to Hearthstone with pics. I will contact Best Fire (installer) to see what they say. I think I could probably put a new gasket in myself. Seems like its a gasket the bypass door rests on when it gets closed. Wish me luck!