How to Replace Door Gasket

How to Replace Door Gasket

Most modern stoves use fiberglass gasket material around the loading door(s) and sometimes the ash pan to seal them air-tight. This helps to boost heat output and prevent smoke from entering your living space. Generally, stove manufacturers recommend replacing the door gasket annually. You can perform a dollar bill test to check the seal quality. For detailed instructions on inspecting gaskets click HERE.

Recommended Tools:

• New gasket material

• Gasket adhesive of choice

• Tape Measure

• Flat screwdriver

• Wire brush

• Coase steel wool

Insider Tips:

• Many stove manufacturers offer a gasket kit with a pre-cut gasket specifically sized for your model of stove and the adhesive is usually included.

• If you are not sure what size gasket to order, you can measure the width and depth of the door channel to estimate what diameter of gasket will seal the door well. Use the tape measure to calculate the length of door gasket needed.

• We recommend silicone-based gasket glue (such as this bottle HERE) because it’s easier to clean up the next time you replace the door gasket.

Helpful Suggestions

• ALWAYS allow the stove to cool completely before attempting to service gaskets.

• Wear long sleeves and gloves when handling gaskets & adhesives to avoid skin irritation.

Replacing Bulb or “Tadpole” Gasket

Bulb gasket is a little different from a rope gasket because it usually has a round side that tapers into a flat edge. If you cut a cross section of this gasket it would resemble a deflated balloon shape or the body of a tadpole. This kind of gasket is usually self-adhesive on the flat edge and then folds over the glass or some sort of frame to create an airtight seal. This type of gasket is less likely to be found at your local hardware store. Refer to your stove owner’s manual for the correct part number and replacement instructions.

Quadrafire uses this type of gasket for several models of pellet stoves including the Castile, Castile Insert, Santa Fe, Santa Fe Insert, and Mt Vernon (Non-AE). To download detailed tadpole gasket installation instructions from Quadrafire, click HERE.

How to Replace Rope Door Gasket

The most common type of gasket used to seal a load door or ash pan is a braided rope style gasket. This rope gasket sits in a groove referred to as a channel and is held in place by adhesive specially designed for adhering the fiberglass fibers of the gasket to the cast iron or steel stove door. The adhesive is readily available at your local hardware store.

Step 1: Remove the Door

Begin by removing the door from the stove (if possible) to work on a flat surface.

Step 2: Remove the Old Material

Pull the old gasket away from the door. You may need a flat screwdriver to chip away the old gasket adhesive. Once all the clumps of old cement are gone, use a wire brush and/or steel wool to scrub the groove until all traces of the old cement are gone. This allows for a strong seal with the new adhesive.

Step 3: Cut Gasket (If Needed)

Measure the length of the perimeter of the door with a tape measure. We recommend allowing an extra inch of material when cutting the gasket material to fit. If using a gasket kit that comes pre-cut from the manufacturer, this step may not be needed.

Step 4: Apply Adhesive

Carefully apply a continuous bead of gasket cement directly into the channel of the door. You want to use just enough to secure the gasket to the door without excess oozing everywhere once the door is closed. If gasket adhesive does leak out of the channel you can wipe it away with a damp rag before it dries.

Step 5: Install the New Gasket

Gently press the gasket into the channel of the door. The flat edged screwdriver or something similar may be helpful to push the rope into its channel. Be careful not to stretch or bunch up the gasket material. Stretching the gasket too thin will create an ineffective seal. Bunched gasket will block the door from closing properly. Start at one end and work your way around the door, taking special care to secure the corners. Trim off any extra material and tuck the ends snug against each other.

Step 6: Test the Fit

Now you’re ready to reattach the door onto the stove and ensure that it properly latches closed. If you have trouble closing the door, you may need to push the gasket deeper into the groove.

Step 7: Allow Time to Dry

Open the stove door and allow the cement to dry. Depending on the adhesive of choice you may need to wait 1-24 hours before lighting the stove again. Some gasket cement is heat cured. This means you will need to build a gradual fire for it to harden completely. Read the directions on the package for the recommended drying procedure.

Replacing Glass Gasket

Glass gasket is usually a flat and self-adhesive strip that wraps around the edge of door glass to prevent air leaks. This improves the burn process inside the firebox and prevents smoke from escaping into your living space. It’s a good idea to replace the glass gasket whenever you replace the door gasket. Brown streaks on the glass around the doorframe tend to indicate an air leak as a result of gasket that needs to be replaced.

Step 1: Clean the Glass

Carefully peel away the old gasket and clean any residue remaining from the old adhesive. Starting with a completely clean surface will ensure the new gasket adheres securely.

Step 2: Lay out the New Gasket

Spread out enough gasket to wrap around the glass on a flat surface.

Self-adhesive Gasket – If you are using self-adhesive gasket all you need to do now is peel away the backing and leave it sticky side up.

Non-adhesive, Flat Gasket – You will need to apply a thin layer of cement to adhere the gasket to the glass. Be careful to use just enough to adhere the gasket to the glass. You can wipe away any excess with a damp rag before it dries.

**Round, Rope Style Gasket -**Refer to your owner’s manual for installation instructions specific to your stove model. Generally, the round gasket should be applied to the surface of the glass that faces the doorframe, so it is between the door and the glass when installed in the stove.

Step 3: Wrap the Glass

Position the edge of the glass in the center of the strip of the gasket and press them together. Carefully rotate the glass until each edge is covered and you return to the starting point. Trim away any excess material so that the ends meet cleanly. Note: You may not need to wrap all 4 edges completely because some models leave a gap along one or more edges to allow air flow to keep the glass cleaner. This is called an air wash. Now fold the gasket against the flat surfaces on either side of the glass.

Step 4: Allow Time to Dry

Depending on the adhesive of choice you may need to wait 1-24 hours before reinstalling the glass into the stove door again. Some gasket cement is heat cured. This means you will need to build a gradual fire for it to harden completely. Read the directions on the package for the recommended drying procedure.

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