UPDATE:
SBI decided to warranty this stove. A replacement arrived last week.
When I last posted, SBI had sent the issues with this stove to their Quality department. It took weeks to get any more information from them. I would send a nice email every week asking for a status. I usually included a photo or video (like below). They went unanswered.
Eventually they suggested that I try a 3/4" gasket (vs 5/8") that they were sending me. But it did not get sent until I asked about it a week later. The 3/4" gasket turned out to be way too big. They also asked if the lower section appeared to have been welding this way or did it appear to have changed over time. I dug into the stove and provided a full explanation about how I felt the front of the stove was manufactured in such a manner that the lower front was pulled back inward during the welding process. Two weeks later they asked the same question.
Then the issue got sent to the service department. When asked what they do, I was told that the service department does warranty replacements. Various department heads have to sign off on replacements. I had never requested a warranty replacement stove. After inquiring about the status I was told three weeks later that a replacement stove would be sent. It took another month for the stove to actually arrive.
When the stove arrived, I checked the area below the door opening. It also angles inward similar to my original stove. It may not be quite a much. The door does seal completely around; top; sides; and bottom. I did notice that the OEM door gasket is a different material and weave than the the replacement door gasket kit SBI sells. (AC06500). I took the door from my replacement unit and put it on my original unit. The door did not seal at the bottom.
Therefore, I have a replacement unit which does seal completely. SBI did not want the original stove returned. I will use it for spare parts; baffle, bricks and burn tubes. While I appreciate that SBI stood behind their product, it was frustrating that the communication was so sparse.
I now hope that this winter I can spend less time fidgeting with the stove. I want to be able to get the heat from the stove and not have it go up the flue. I want the secondary flames to burn via the burn tubes and not at the front of the stove. Time will tell.
