How about adding forced air induction down at the coal level, some sort of blower like a guy would use for..a forge, something like that?
If you think back zogger, I tried something sort'a like that.
At the bottom front is a small "boost air" hole, which is distributed through a manifold thingy... it's designed to supply a little air at floor level during start-up (because EPA tests require the door be closed shortly after lighting). I drilled more boost air holes... first just a couple, then more, then more, etc. It didn't change a thing until I removed the firebrick from the floor and installed a coal grate an inch or so off the bottom. Man, that thing worked awesome with the extra floor air and grate... except, that inch under the grate would fill up with ash in a single loading. Cleaning out the ashes was a royal friggin' pain; ya' had to lift out the grate, which would only fit through the door at an angle... and ya' had to do it after every burn cycle (meaning ya' pretty much had to let the fire go out). And trying to raise the grate to a reasonable level reduced firebox capacity way too much... I ended up pluggin' the holes and reinstalling the floor brick.
I thought about cuttin' the floor out, welding in an ash collection cavity, and installing the grate permanently... but that would have meant a total re-engineering of the whole stove. All three air intakes... primary, secondary, and boost... are under the floor, and so are the doors and control linkage (run by a single lever on the front beside the door). Primary and boost air use the same internal passage channel (making forced air problematic), secondary has its own. Heck, it would have been easier to build a new box from scratch.
That experiment confirmed something (to me anyway). Burning on a grate, with at least
some combustion air fed under it was way, way, way better... the difference was friggin' amazing. And I still had good secondary combustion‼ No doubt it would have failed the EPA tests configured like that... but it sure worked a ton better‼ Way more heat for way longer and no coal build up (until ashes filled the area under the grate).
Like I said in a previous post in this thread... elitist stoves are designed to pass EPA testing, they ain't designed to be "better". I'm sure the manufacturers do the best they can within the "regulatory limits", but the first and foremost consideration
has to be passing the EPA testing or your product is rejected... anything else
has to come a distant second. Those new proposed regulations that likely will be approved sometime early next year are gonna' make it interesting, and problems such as I (and a few others) have had will become a lot more commonplace... mark my words‼ Mark my words‼
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