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[oaky]

It seems if the ash door is correctly sealed tight, there shouldn't even be moisture dripping from the ash door. If there is, then it's allowing cold air in. I'm not saying that condensation won't occur from the boilers first start up of the season, because it will condensate for a short time, it will with all makes of owb's. But, if it continues to drip out of the ash door, odds are, that the door needs to be adjusted more tightly, or the gasket may not be applied correctly, etc.

Applying a coat of silicone does add that extra layer of thickness that was needed to seal any air leak(s).

I'm glad P&M went with silicone gaskets on there units, it does create a better seal.

[Jwood]

The only problem with adjustment of the ash door is that there is no adjustment short of bending the handle and I'm not doing that.

[oaky]

There is a nut that secures the handle to the ash door, if it isn't already turned all the way in, it can be turned in a bit more, this will cause the handle to press against the door latch creating more pressure on the door for a tighter seal.