Quote Originally Posted by ecolbeck View Post
I have the same arch with the drop flue pan. I encountered all the same issues you did. I don't think the unit was designed with insulation in mind. I notched my bricks so they would fit and allow the grates to be removed using an angle grinder. Also, your grates are upside down. Place them vee up so that ash can collect in the vee and insulate the metal from the fire and prevent warping. I can take pictures later if you would find that helpful.
Thanks. I'd love some pictures. You did use the 1" insulation? Did you use bricks from the ramp to the stack as well?