Expert: Bart Ogden - 9/25/2007

Question
Hi Bart,
We have a heavily used and abused steel firebox that is part of a Heatolator fireplace that was installed in early 1980. During the NY Fall, Winter, and Spring my father would burn the fire nonstop from 5 am until midnight. He abused the fireplace by burning with the glass doors closed and the damper almost closed. He believed this would build the heat in the firebox and slow his wood consumption thus maximizing his home heating by the use of the Heatolator fans. This late summer I have discovered an 1/8th inch horizontal crack about 15 inches long in the steel panel directly to the rear of the firebox. This panel is 15 inches tall and 27 inches wide so there is an equal 6 inches on each side of the crack up to the welded seam on the sides. I have also discovered a bulge and some stress fractures in the steel panel that angles up above the one with the crack and leads to the damper. This bulge is low on this panel, and within 8 inches or so of the crack in the panel below. I did have a certified sweep inspect this and he suggested ripping the face off of the fireplace, cutting the box out, and replacing it with a brick style firebox. He also explained that since the 1980's they have determined it is more energy efficient to get rid of the Heatolator setup, which I believe as well. I asked about other repair options, such as a repair weld or plate, and he said they don't have any such item. On the Internet I have found certified sweeps and companies that offer to repair cracks by use of boilerplate steel, and heat treated self tapping screws. I have found that they will also weld, but warn about possible plate warpage when this is done. My first thought before I had anyone look at the fireplace was to make a template of the cracked panels out of poster board. I would make the dimensions from welded seam to welded seam of the existing panels, and then have duplicates cut out of the appropriate steel and welded in place. What are your opinions on these options or your experiences in regard to this scenario. Thank you! Shawn

Answer
Hi Shawn,

If the firebox is that heavily damaged, you need to replace the assembly.  The certified chimney sweep has EXACTLY the right advice for you.  Follow it.  Don't try to patch this.  

Thanks for using AllExperts.Com and good luck with your project.

Sincerely,
A. Bart Ogden, President
Home Safe Hearth & Chimney, Inc.
Wichita, KS
Voice: 316-265-9828
Fax: 316-265-9890
www.homesafeks.com