Hi everyone, First post! Looks like I found a great forum. I am on my third season with my Napoleon 1402 insert and am having an issue you experts might be able to help me with. SMOKE...and lots of it. I cant open the door more than a crack and it just pours out. The odd thing is that when the door is closed, it seems to burns just fine. This all started happening around the time I replaced the factory baffles that were starting to fall out in pieces. The new baffles are much thicker. They are 2"+ and the old ones were more like 3/4ish. I have a "chimney guy" who gives me a good cleaning every season, so the pipe is clean. I have a tall stack (37ft+) and being an insert its 6" SS liner/pipe inside the masonry chimney. He is saying that I "used a ford part on a chevy" since they are obviously thicker and the reduced airspace is causing the backup since the pipe is clean. I explained that the original baffles are no longer available and these are the replacement, bought from a Napoleon distributor, but he still thinks they are the wrong ones. I am wondering if there is something going on up at the top as he cleans the flue from the bottom. This is a 150yr old farmhouse with a steep roof pitch and very tall chimney...I don't have a ladder nearly big enough to get up there myself. From the ground it does look like there is some creosote on the cap, but I wouldn't call it clogged. It's a large cap as well since it's on the masonry and not the pipe itself (about 2-1/2ft x 1ft square). Soooo....my questions is: Does his hypothesis sound right? Could the new baffles be causing this? My wife suggested we take one baffle out completely for one load just to see if it keeps smoking. Good idea? Thanks!