Had the first problem with my boiler and it wasn't a small one. I noticed a few rusty spots developed over the winter... thought they were surface rust and I'd fix them this spring. A couple weeks ago I got out the wire wheel and punched through the door in a few places. Called the dealer, covered under warranty, and delivered today. New door was easy to install and fits perfectly.
Looks the same but mounted slightly different. Dealer said he had a couple do this but it wasn't common.
I've been burning the boiler daily for DHW since I replaced the door. I'm sitting here watching it burn have noticed that it is running a lot cleaner since replacing the door. The damper plate used to require cleaning and lubrication every so often and I haven't had to that since the replacement either. I think the old door was leaking pretty good....letting too much air into the firebox than the secondary burn could handle....and caused it to smolder after the burn cycle and gum up my damper plate.
End of season, if it was mine, I'd put on down flat on a welding table and overlay a sheet of metal on it.
That beats Central Boiler. They put a "Lifetime Warranty" sticker on my cast iron door. It developed a crack and they said I had to buy a new one. It wasn't covered. Pretty sad. I'll add I've never overheated my stove either.
