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A little exploratory chiseling on my Nature's Comfort NCB-250 owb this morning revealed an enormous fountain of water inside the door. Plugged hole with modeling clay. Drained the boiler into 5 gallon buckets, cat sand jugs, trash cans whatever. Filled a trash can to Acquired a needle scaler from my friend in Mac tools, love it. Found many holes in a huge hurry.

I'm no welder so dad is using his Miller MIG on it. However as it got dark the fan quit cycling and the welder stopped working. We're hoping it just needed a break, too dark for pics.
House is holding 63 degrees currently.
IMG_20201127_143203931_HDR.jpgIMG_20201127_143206719_HDR.jpg
 
Good luck with the repair. I had to have two pieces of metal rolled and 20 pounds of 7018 rod was used on my Garn June of 2019 to repair a major crack were the main heating chamber is welded to the front of the unit. It started leaking Dec of 2018 and I kept added water to get me threw till spring.
 
That is not looking good. You might want to hire a pro welder and let them have a crack at it. Might be able to put a patch or enough bubblegum over the holes to get you through the winter. Even if it weeps a little. I would recommend you call your local rep or the company direct and ask about having the boiler rebuilt next summer. We had a CB rebuilt and even with the shipping, it was way cheaper than a new unit. Good Luck.
 
Problem with that is even though you only see a few small holes the metal is wore super thin. If you can manage to fill those holes without making new ones when welding they won’t last any real length of time. Hate to say it but your gonna have to cut out that section and see how bad the damage is so you can see how big of a repair is necessary. Good luck on the repair.
 
IMG_20201128_150556421_HDR.jpgIMG_20201128_160624334_HDR.jpgIMG_20201128_160621127_HDR.jpgIMG_20201128_143739376_HDR.jpgstill leaking as of last night on the right, picture 2. Stupid welder made it take all day. Going to bypass one of 3 thermostats in the welder and rig it up for fan always on for now. Dad plans make a pass all the way around the inside edge of the door and touch up some areas he felt were suspect. Nothing leaked on the cold fill. Requires draining it again. Back breaking job!!! And the lights back there in the basement haven't been installed yet. Lucky I have a garden hose attachment and valve on the bottom of the system.

Do have heat now, but Using my 2nd garage in-floor as a heat sink to cool the water down enough for drain of the stove number 3.

The door gasket had been replaced but it actually rust jacked so bad it pushed the gasket out a full inch past where it should be. Door wouldn't close anymore regardless of the adjustment. It had been leaking for years. Took an hour to clean the scale off the gasket groove with a hammer, the scaler couldn't get in there that well and couldn't finish the job. Luckily a friend had a tube of good fire caulk at 7pm as all the hardware stores closed by the time I realized my TWO tubes were no good to install the gasket. Tight as a drum now. No doubt this air leak contributed to the corrosion issue as well as other issues such as a pesky temp climb on warm days etc.
630 am to 900 pm working on it yesterday.
 
Pics of the last repair.
Ground in to the original seam weld and sealed it out to the repair.
 

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