Vermont Castings 3440 Installation Instructions

Gasket Kit #3440
Installation Instructions
for the Vigilant, Resolute,
Intrepid, Intrepid II and
1975 - 1988 Defiant* stoves
Vermont Castings' stoves use a rope-type gasket to
make a seal between some parts. With use, this gasket
can become compressed and begin to lose its effective-
ness. It should then be replaced. *1975 - 88 Defiants
do not have glass in the front doors.
Contents
4' of steel reinforced griddle gasket
12' of 5/16" door gasket
5' of 3/16" glass gasket
1 tube of gasket cement
Tools Required:
Utility knife
Rubber mallet, or hammer and block of wood
Wire brush
Flat-blade screwdriver
Installation Precautions
Wait until the fire is out and the stove has cooled before
replacing the gasket, and be sure to follow the stan-
dard safety procedure for working with dusty materials:
Wear safety goggles and a dust mask.
Installation Instructions
On most stoves you can remove the door(s) simply by
swinging them back and froth while lifting, to free the
hinge pins from their supports. Set the door(s) down on
a flat, padded surface, such as a rug scrap or old towel.
The procedure for replacing the gaskets is the same,
regardless of stove type.
1. Remove the existing gasket by grasping an end and
pulling firmly.
2. Use a wire brush or the tip of a screwdriver to clean
the channel of any remaining cement or bits of
gasket. Remove stubborn deposits of cement with a
cold chisel if necessary.
3. Determine the correct length of the appropriate-sized
gasket by laying it out in the channel. Allow an
extra 1-2" (25-51 mm), and mark the spot to be cut.
Fig. 1 Remove gasket then clean channel with wire brush.
4. Remove the gasket from the channel, place it on a
wood cutting surface, and cut it at the marked spot
with a utility knife. Twist the ends slightly to discour-
age the gasket from unraveling.
5. Apply the cement in the channel. Before you cut the
tip of the cement tube, however, knead the tube thor-
oughly to help mix back into the cement any water
that may have separated during storage. Practice
applying the cement on a piece of newspaper before
you actually place it in the channel.
Once you are familiar with the technique, lay a thin,
unbroken 1/8" (3 mm) bead of cement in the chan-
nel. Avoid saturating the gasket with the cement. If
saturated, the gasket will lose its resiliency.
6. Starting at one end, press the gasket into the chan-
nel. Ensure a good joint where the gasket ends meet
before trimming any excess. Do not overlap the
gasket ends or leave ends with ragged edges.
Fig. 2 Lay a bead of gasket cement then press gasket in
place.
7. Replace the door(s) by aligning the hinge pins with ST559
Remove
the supports, and pressing down gently. It may help
gasket
to swing the door back and forth gently as you press
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down. Press the part firmly against its normal mat-
ing surface to seat the gasket evenly in its channel.
ST559
Remove
gasket
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2008844 7/08 Rev. 10
ST560
ST561