Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 1 o10 3/7/07 Travis Industries, Inc.

Compatibility

This kit is for Leyden wood stoves with a warped or bent bypass rod. Because the rod is not visible inside the firebox, the only way to determine if the rod is warped is the tensioner bolt. If the bypass does not stay shut, and the tensioner bolt is screwed fully in*, the bypass rod is likely warped and will need to be replaced.

This kit contains an improved bypass rod made of stainless steel. This improvement is in all Leydens manufactured after 2/16/2007 (Rev 002). If you are uncertain if the bypass rod is stainless-steel, remove the bypass handle and check the rod. If it is stainless-steel a magnet will not stick to the rod.

The tensioner bolt should be 1” long to provide the necessary adjustment on the bypass rod assembly. If the installed bolt is too short, replace it with an included 1” bolt and test bypass adjustment. NOTE: The bypass rod may be warped by the tensioner if this bolt is over-tightened repeatedly (the tensioner deflects the rod until it starts to bend). When adjusting the tensioner bolt, tighten it only enough to keep the bypass shut without excessive effort on the bypass handle.

Packing List • Stainless-Steel Bypass Rod • Interram Gasket • Combustion Brick Gasket • (4) ¼-20 1/2” Bolts • (4) ¼-20 1-1/2” CS Bolts • (10) ¼-20 Brass Nuts • (2) ¼-20 1-1/4” Bolts • (4) ¼-20 1” Bolt • # 7 (.204”) Drill Bit • 9/32” Drill Bit • (2) 10-24 3/8” Screws

Installation

NOTE: The bypass rod is accessed through the firebox. We recommend that you lay down a drop cloth and clean the firebox prior to conducting the steps below.

1 Remove the doors and place them aside. Remove the top loading door and place it aside.

2 Remove the side firebacks (and clips) and place them aside.

Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 2 o10 3/7/07 Travis Industries, Inc.

3 Remove the back heat deflector and place it aside (the allows for access to the nuts that hold the firebox back plate in place).

4 Remove the back brick retainer holding the back brick in place (“U” Brick).

NOTE: The ½” bolts holding the retainer in place are used only to hold the brick in place. If one of these bolts breaks off, we recommend that you leave the threaded portion inside the cast iron damper assembly. Two bolts are sufficient for holding the retainer in place. We have included two 10-24 3/8” screws if additional fasteners are required (use an 11/64” drill for pilot holes).

NOTE: When replacing the retainer, use the included ½” ¼-20 bolts included with this kit.

Three bolts hold the back brick retainer in place.

Damper Assembly

Four nuts hold the back heat deflector in place.

Back HeatDeflector

Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 3 o10 3/7/07 Travis Industries, Inc.

5 Remove the back brick, interram gasket and combustion brick.

Back Brick Combustion Brick Interram Gasket

6 Remove the combustion brick gasket (located on the floor of the firebox, directly in front of the combustion box).

Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 4 o10 3/7/07 Travis Industries, Inc.

7 Remove the firebox back plate. You will need to unscrew the four countersunk screws from the front while securing the nuts on the back of the stove.

Use a phillips screwdriver to remove the 4 screws Firebox Back Plate Secure the nuts on the back of the stove

Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 5 o10 3/7/07 Travis Industries, Inc.

8 Remove the two bolts and nuts holding the damper assembly in place. Remove the damper assembly.

Remove the two nuts above the damper assembly Remove the two bolts to side of the damper assembly

When removing the damper assembly, take care to not damage the combustor.

NOTE: If either of the bolts holding the damper assembly breaks off, use the included #7 drill bit to drill out the broken bolt (drill from the back side). If the threads on the stove are damaged while drilling, drill out the hole with the 9/32” drill bit and secure the assembly with the extra 1-1/4” bolts and nuts included with this kit.

The damper may swing open while removing the damper assembly. Use both hands to secure the damper.

Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 6 o10 3/7/07 Travis Industries, Inc.

9 Remove the bypass handle (use a 1/8” hex wrench).

10 Remove the clip on the right side holding the damper rod in place.

NOTE: If this bolt breaks off, use the included #7 drill bit to drill out the broken bolt. If the threads on the stove are damaged while drilling, drill out the hole with the 9/32” drill bit and secure the assembly with the extra 1” bolt and nut included with this kit.

Remove this bolt and clip to the right of the damper rod.

Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 7 o10 3/7/07 Travis Industries, Inc.

11 Slide the damper rod down and to the right to remove it from the appliance.

12 Install the stainless-steel damper rod.

13 Replace the damper rod clip (use the included ¼-20 1/2” bolt, do not use the bolt that was removed from the stove).

Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 8 o10 3/7/07 Travis Industries, Inc.

15 Re-attach the damper handle. Position the damper so it is angled slightly forward. This will help during re-installation of the damper assembly.

16 Replace the tensioner bolt on the damper assembly (the upper bolt on the damper plate) with the included 1” bolt and nut. The bolt should be inserted so it does not tighten against the tensioner plate. Tighten the nut against the damper plate to insure the bolt does not back out.

Tensioner Bolt (with Nut Attached)

Damper Plate Damper Assembly

Tensioner Plate (on the back side of the damper plate)

Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 9 o10 3/7/07 Travis Industries, Inc.

17 Replace the damper assembly. While positioning the assembly, hold the damper slightly open, this allows the rod to slide over the ramp on the damper.

While installing the damper assembly the damper rod will slide over this ramp.

Leyden Wood Stove Stainless-Steel Bypass Rod

SKU 250-00622

Page 10 o10 3/7/07 Travis Industries, Inc.

18 Secure the damper assembly (use the included ¼-20 nuts and ¼-20 1-1/4” bolts, do not use the nuts and bolt that were removed from the stove).

19 Test operation of the damper before replacing the other components. The tensioner bolt will probably need to be backed-out fully for the bypass to operate.

20 Replace the stove components (use the included ¼-20 nuts and ¼-20 bolts, do not use the nuts and bolt that were removed from the stove). Use the included gaskets during re-assembly.

Tensioner Bolt