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[loneryder]

This is the main problem I see with spray foam issues as ive said for years on here, they can hide simple fixes and then by the time you find them, a lot of damage has taken place

Well mine certainly did.  I figure a pinhole from the factory and the foam held the water against the outside of the sheet metal water jacket.  After a year and half, it's eaten through.  I think they should bring me a new boiler and then take this defective one back.  If it were several years old, they could argue too many variables.  This is the second winter of a boiler manufactured 11/11.  It's been rusting for a long time.  Original fill with anti corrosion material by the dealer who know what they are doing.
What kind of insulation do you recommend?

[loneryder]

Well this is interesting.  Since the back of my 5036 is bare metal and the temps were heading down for the next 10 days, I placed a strip of faced R19 insulation across the back and secured it with duck tape.  Fired it up 2 days ago and with the night temps around 0, I'm getting longer burns.  I load it up about 9 at night and it still had some wood at  10-11 the next am.  Happened for 2 days now.  Before, there would be nothing but a few coals at warmer temps.  So I'm wondering if the R19 is better than that 3" of foam they spray on it?

[pwdiver]

Im glad to hear you got the boiler up and running again, Ive had my boiler running since 2009 and had the water temp at 180 degree's with 6-8 inch's of snow on the top not dripping anywhere.