Success! We finished the installation on Saturday, as an unscheduled Black Friday excursion popped up and the crew mutinied for a while.
What worked well:
1. the installation videos on YouTube were very helpful, and provided us with good methods.
2. the reman unit was an exact fit. Add a few dollars for door insulation, fiberglass insulation, and aluminum tape. The reman unit shipped with spray foam insulation and a bit of tape, but not really enough to cover the inevitable tape snarl.
Surprises:
1. Dirt wasp nests, actually more like condos. The little buggers went around the screen and had so many in there they actually impeded getting the unit out.
2. Sodium Chromate travels further than expected. It took a lot of wire wheel and wire brush cleaning to get it out and off the components. I had both on hand, but to do it right takes extra time.
3. The smallest roll of fiberglass insulation is 15" x 40'. Enough to re-line the flue and the enclosure, too. We used 3M spay glue to stick the insulation into the enclosure.
4. the electric strip looked pretty used up what we got it out of the boiler tube, but it went right back in and works. I checked it with the multimeter and got 40 ohms, so save a few bucks there.
5. Only one stripped screw head in the project, and it was between the cooling fins. I wasted a couple of hours trying to do the right thing with easy-outs and then just drilled it out.
Got it all re-assembled and wired, hooked up the propane line, and tested the gas function first. It needed a few re-lights as the air came out of the lines and it burned blue (Yippee!). Went to the electric strip and everything is cold inside.
The Eagle has landed...