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[hondaracer2oo4]

I had my boiler spray foamed after I bought it 3 years ago. Soon after the boiler started steaming from around the flue. I called hardy and they said it was a common issue and that to fix it I needed to remove the top of the water jacket and rechaulk where the top of the firebox meets the top of the water jacket. This would be easy if I hadn't spray foamed the whole water jacket. So I have lived with it steaming around the flue for 3 years. I have tries to chaulk between the flue and the water jacket from above with high temp silicone but it always fails within a month. I add about 5 gallons of water every week. Anyone think it would be worth doing it right to increase efficiency or just live with adding water every week?

[freefour]

Do you have a hot water loop?  I do and it autofills the tank.  If you could hook that up you wouldn't have to worry about it. 

However, in most cases I try to do things right.  If it was mine, I would remove it and caulk it then replace the installation.

[hondaracer2oo4]

No, I decided not to utilize the dhw loop in the boiler. I went with a sidearm in the house instead. I placed a T in the return line to the boiler inside the house with a quarter turn valve plumbed to the domestic water, thats what I use to refill. I was wondering how much efficiency I am losing with it leaking like it is.