My bottom panel crumbled and I couldnt source a new one, so I made a new one with Rutland castable refractory cement. All went well and I just installed the new panel. I tried to make it the same thickness as the old panel, the old one was 1" and the new one is a little over over 7/8" thick...so darn close. I used the original parts including these metal shims which support the side panels. I end up with a 1/4" gap in the back but the front is about flush. I verified the thickness was even all around the new panel so I'm not sure the exact cause, maybe the metal box has sagged over time?
So, my question, should I caulk that gap? Buy more cement and cast small panels (say 2"x2") to just sit along each side to obstruct the gap? Or trim the metal shims with an angle grinder to slope rearward and close the bottom gap, which may open the vertical side gaps slightly. The last photo shows how the metal shim and how much the side panel overlaps the bottom panel. I considered just removing the metal shims all together.
I have attached some photos. We just burn small fires for ambience. Thanks for any help!
![[Hearth.com] Options for gaps in refractory panels](https://www.hearth.com/talk/data/attachments/321/321303-60c6591d77a4ba0907ee8632ae2b70ef.jpg?hash=JLdgAU2BFF "[Hearth.com] Options for gaps in refractory panels")
![[Hearth.com] Options for gaps in refractory panels](https://www.hearth.com/talk/data/attachments/321/321304-d5c45822b15fd26ab74be3a92a2831e8.jpg?hash=UiLAr-nlBG "[Hearth.com] Options for gaps in refractory panels")
![[Hearth.com] Options for gaps in refractory panels](https://www.hearth.com/talk/data/attachments/321/321305-f4ad6ad98c5428ba74ddfdec21424bb3.jpg?hash=WVYKEaE0qk "[Hearth.com] Options for gaps in refractory panels")
![[Hearth.com] Options for gaps in refractory panels](https://www.hearth.com/talk/data/attachments/321/321306-ea3decdee8b7880d16270abfbfb4ca04.jpg?hash=zD7GYYLvX0 "[Hearth.com] Options for gaps in refractory panels")
![[Hearth.com] Options for gaps in refractory panels](https://www.hearth.com/talk/data/attachments/321/321307-b0bdbdfb18e47a8200d46ea495b17151.jpg?hash=EIb1I0TGlv "[Hearth.com] Options for gaps in refractory panels")
![[Hearth.com] Options for gaps in refractory panels](https://www.hearth.com/talk/data/attachments/321/321308-aa6b462059af465af69628d4fae9925d.jpg?hash=XEes095Rbz "[Hearth.com] Options for gaps in refractory panels")
![[Hearth.com] Options for gaps in refractory panels](https://www.hearth.com/talk/data/attachments/321/321309-a1736fa55561396a3c860080f1b046e7.jpg?hash=JrWNPH8a2J "[Hearth.com] Options for gaps in refractory panels")
![[Hearth.com] Options for gaps in refractory panels](https://www.hearth.com/talk/data/attachments/321/321310-0a55a3609535d3f817a65505bcc31ee3.jpg?hash=P_zV4G1FPR "[Hearth.com] Options for gaps in refractory panels")
![[Hearth.com] Options for gaps in refractory panels](https://www.hearth.com/talk/data/attachments/321/321314-265dac3244ec7e734ceb726a25024592.jpg?hash=-5gKi7O4Vx "[Hearth.com] Options for gaps in refractory panels")
So, my question, should I caulk that gap? Buy more cement and cast small panels (say 2"x2") to just sit along each side to obstruct the gap? Or trim the metal shims with an angle grinder to slope rearward and close the bottom gap, which may open the vertical side gaps slightly. The last photo shows how the metal shim and how much the side panel overlaps the bottom panel. I considered just removing the metal shims all together.
I have attached some photos. We just burn small fires for ambience. Thanks for any help!
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