How to Replace Stove Door Tadpole Gasket - Quadra-Fire Pellet Stove

[@jeffinwa2781]

I did mine just like you did, also had problems replacing the retainer rods. With lots of patience, the rods finally went into the holes. I fired up my Castile and after about 10 minutes of flame, the glass cracked.

[@EarthSense]

So sorry to hear that. It's a tricky gasket and installation. The rods do put a good amount of pressure on the glass. Generally speaking as long as the rods are on the flat part of the gasket and not the bulb, things are good, but there can be several factors such as the thickness of the flat part of the gasket and how the glass seats inside of the door frame - or any defects/bulges/debris in the door frame creating a difference in height when the glass is laid in place. It may be good to inspect the door frame closely to see if you notice anything that is off. The replacement glass comes with the gasket pre-installed from factory. Here it is for reference - pellethead.com/product/quadrafire-castile-santa-fe-door-glass-assembly-w-gasket-oem/ Again, so sorry to hear about this frustrating experience, anything else we can do, please let us know. Appreciated.

[@benmiller6136]

Very helpful tutorial thank you.

[@EarthSense]

Glad the video was helpful. Please let us know if you have any other questions. Thanks!

[@LagansLove]

Thank you!! I have tabs so hopefully folding them over isn't tricky. I'll bookmark your website for future issues.

[@EarthSense]

You're Most Welcome! Yes, tabs are far easier than the rods. Try to only bend the tabs over once to release the old gasket and bend them back down once to secure the new gasket. The more the tabs are bent/moved back and forth, the less security they provide. Any questions as you go along just let us know. Always happy to help!

[@kayomototo]

Someone told me the pellet stove need to form a vacuum and the seal must be all arround. I can't find anything in the manual. Do I really need a air gap at the bottom? By the way, thanks for the video.

[@EarthSense]

Thanks for the message, glad the video was helpful. The air gap is for the 'Air-Wash' system. It can be sealed all the way around, you will just find that the glass gets dirtier more frequently. Many makes and models will have an air-wash system to help keep the glass clean. Some units have a small gap on the door or glass, other units will draw partial air from the intake to keep the glass clean. The air-wash system is approved by the manufacturer and meets all regulations. It is important there is proper seal around the firebox for most pellet stoves to have proper vacuum and pressure; the air wash gap is pretty small allowing a minor amount of room air to be sucked in and up the glass during operation. Any other questions please let us know. Thanks.

[@michaeladams3102]

Thankyou for your time videoing! Did you accidentally put glass in upside down with the space at the top?

[@EarthSense]

Looking at it closely, yes it appears that happened by accident. Apologies on that. Some units had the air-wash at the top, but most had it at the bottom. Important for the replacement to be the same way as the previous was installed. Appreciate you pointing that out.

[@TBONENYC]

Thank you so much for posting this video! It is just what I need! I have the same exact model with the retainer bars . Do you have a link for the exact tadpole gasket that I need? I’m not sure of the diameter or length that is needed. I found one on Amazon that says 1/2 in or 3/8 inch

[@EarthSense]

Sure thing! Glad the video was helpful. Here is a link to the 5' length Tadpole gasket for Quadra-Fire: pellethead.com/product/pellethead-replacement-quadrafire-tadpole-door-gasket-seal-5/ And here is the link for the 10' length Tadpole Gasket: pellethead.com/product/pellethead-replacement-quadrafire-tadpole-door-gasket-seal-10/ Any other questions or assistance needed please let us know. Appreciated.

[@TBONENYC]

@@EarthSensejust ordered it from your Amazon store! Thanks again !!

[@EarthSense]

@@TBONENYC Great, thanks so much! Definitely reach out on here if you have any questions while installing. Patience is a virtue while Installing this gasket in the Quadra-Fire door with the retainer rods - you got this!

[@kolipo]

Thanks. This helped me on my castille insert rebuild.

[@EarthSense]

Glad to hear it was helpful! If you need anything else just let us know.

[@susandavis2134]

Great video. I love my Castille pellet stove insert. It may be old but with regular cleaning it works flawlessly.I had the local dealer come out for a maintenance visit & to install a new gasket. My door has the retaining bars & the air wash is at the top.the technician installed the bars under the bulb gasket. The glass broke the first time the stove lit and ran for more than a few minutes. I believe the diagonal crack to be caused by thermal expansion. They claim it is not related to the gasket installation. Is there a service manual or other documentation you could suggest that I can refer them to?

[@EarthSense]

Thanks for contacting us. I just looked through our old Quadrafire Castile manuals and service manuals, however there is no diagram or detailed information for replacing the tadpole door and glass gasket. We have been selling and servicing the Castle stove since it first arrived on the market. The design with the rods is a bit trickier as you see in the video compared to their later design with the fold over tabs. I do believe the door frame with the tabs is something that is available or can be ordered should you want to get away from the rod security design. If the rods were not installed over the gasket once the bulb was folded over, they could be putting additional pressure on the glass. Additionally for the bulb to seal properly against the door frame, the rods need to be over the gasket like you see in the video, otherwise the bulb would not be stable to create the seal when the door closes. If you need the owners manual or if we can help in any other way please let us know. Happy to assist. Thanks.

[@susandavis2134]

Thank you. I wish I lived in your service area but I live in Tacoma WA. The model year of my insert is 2005 serial number. 0071382906. I moved here in January 2023, as the newest owner of this little 1922 craftsman bungalow, with the cozy pellet stove. I do not have a copy of the owners manual but was able to find one online dated 2014. If you have a link for the one that would have come with my insert I would greatly appreciate it. The same company is retiring Sep 30th to replace the glass & the auger motor. If you don't mind I am going to send them a link to your you tube video & suggest they review their practices before coming out. The auger motor is working fine for now but the tech recognized something in the noise it makes that indicated it is going out. There are a couple of questions I have. One is do I need to do anything other than give it a thorough cleaning when it will not be used? Like treat or paint the firepot? The stove is controlled by an old Honeywell digital thermostat. Is there a newer WiFi thermostat that you could recommend? Thank you again for your help.

[@EarthSense]

@@susandavis2134 Thanks for the message back, always happy to help. I dug through the archives and I found a 2003 Castile Insert owners manual. I believe this will be the most accurate to your 2005 model. Link here - pellethead.com/wp-content/uploads/man_castileinsert.pdf Yes, you are more than welcome to share our videos with anyone. Generally as auger motors start to fail you will either hear grinding/squealing while turning or you will notice fuel feed issues due to the motor getting weak. When the unit is not in use for extended periods of time (summer), after you perform the thorough cleaning we recommend plugging the vent pipe/chimney outside to prevent moisture from coming in. If the stove is in a high humidity area, the interior firebox can be sprayed with WD40 to prevent rust. If it's short term when it's not in use, just the cleaning is good. For the early Quadra-Fire models the original mechanical and basic digital wall mount thermostats were always the most tried and true. They do however offer a remote control thermostat pellethead.com/product/quadrafire-smart-batt-ii-remote-control-thermostat-oem/ As well as a digital programmable wall thermostat now. pellethead.com/product/quadrafire-programmable-wall-thermostat-w-wire-oem/. The newer Quadra-Fire Trekker insert will have a Bluetooth interface thermostat, but that technology isn't there for the earlier models. Hope that is helpful, any other questions please let us know. Thanks!

[@susandavis2134]

Thank you so much! They will be coming out mid October when the new glass arrives & install it & the auger motor. The operations manager offered me a very generous break on the parts & labor to install the new glass & install the new auger motor. I have learned a lot about caring for my pellet stove from you & this whole experience. Thank you so much!

[@EarthSense]

@@susandavis2134 That is wonderful to hear! So glad we were able to be of assistance. Keep us posted how everything is working after your service appointment. Thanks again,

[@markdominguez4645]

What helps is when you go around the corner cut the flat part of the gasket at a forty five degree at the bend. Let’s the bulb not pop out in the corners,which could make the door hard to close . And the doors with the tabs were the 1st generation, and then the rods. Why the change is that if you bend tabs to much they will break off and you will have to replace the door frame. when you put the rods in make sure that the ends with the notches is down. If not over time the rods will fall out. On that note I find when taping the rod in place, put the top in first, then use a screwdriver on the notches to push down and tap in at the same time.

[@EarthSense]

Thanks for sharing your experience and notes Mark. Appreciated!

[@TarotMoon]

I ground a small bevel on the rod to help guide it into the hole during install

[@EarthSense]

Great tip! Thanks for sharing!

[@RedneckYeti]

Thanks for the video

[@EarthSense]

Most Welcome!

[@thepumpkinking6370]

Sometimes if you put a slight bend on the rod it helps angle it

[@hcarmine1]

My door has tabs and not rods so what holds the glass in the frame?

[@EarthSense]

Thanks for contacting us. You will bend the tabs up to release the glass with gasket. Once the gasket is replaced and the glass is placed back in the door frame, you will bend those tabs back down to secure the glass in the door frame. Any other questions please let us know. Thanks!

[@colorado694]

The only thing is that maybe have your girlfriend or someone else to hold the camera while you're demonstrating. It happens a lot with automotive repair videos too. Otherwise the video was outstanding.

[@EarthSense]

Appreciate that, thanks so much!