This page details the part of the work that went into replacing a gas log in a wood burning fireplace with a direct vent monessen BDV300. It has remote start and blower option (more on that later!). We decided to use direct vent to reduce chance of contaminating indoor air and also prevents indoor air from being used for combustion. We used a Simpson co-axial converter at fireplace and one at top of chimney and about 35 ft of corrugated aluminum tubing, one for vent, one for fresh air intake. Due to large height, vent restrictors are necessary to slow donw the air in the columns and to get a good flame, otherwise, air rises so fast that is can blow out the flame.

Update Jan. 2011

Complete - almost

Update Feb. 20, 2009

Finished installing the culture stone from www.culturedstone.com It's a decent product, but does not match pictures they show up. Color is NOWHERE near the photos in the catalog. The fit and finish is not great, especially for a premium product. The corner boxes claim to cover 8 linear feet, not in this hemisphere! Floor to ceiling is 8ft, subtract 1.25" for hearth, subtract 2.25 for mantle and we were still one corner short. We improved. That's a load of crap Dupont - get a better tape measure! My other gripe - lots of broken pieces. I measured my mantle shelf using their specs, 1.25 thick + width of framing + slight overhang = width of mantle. Send dimension to granite fabritator and wala, instant, nice bullnosed granite shelf - that was not so! Some of the corners are EASY 2" thick + 1/4" mortar on each side and your overhand is not GONE! I was fuming! I was going to order a new shelf, wider and deeper this time, but decided to build a oak mantle instead, finished in a dark mohagonny to match a insert around the fireplace on the wood floor.

Now for some pictures in reverse order, finish to start

Wne thru 3 or 4 2x4 looking for nice even, flat one - not chance! This 7ft level was perfect size! We put strip of painters tape on top side, shim on the to level it and shims along the way to carry any load and we had a perfecty level (haha) spacer for our yet to be built mantle shelf.

Here's up close short of the upper half. As you can tell from the 4x4 box, some pieces are fairly large - would definitely not recommend this for small area - lots of cursing and swearing will be guaranteed. On positive note, it is very easy to cut. I used a diamond wheel on rotozip w/ angle grinder attachment at about 25,000 rpms. I had a shop vac setup with hose taped to a 2x4 and I built a small shroud around it, so when i was cutting, all the dust would get sucked into the vaccum. Worked 90% well! Small wheel on the rotozip makes it difficult for some cuts, but its underpowder enough that if it jams, chance to injure yourself is reduced. Safety glasses are a must as stone chips can ruin your day. Ear plugs - also a must, that whine of mtor at 25,000 rpms will leave your ears ringing for days.

Here's the lower half, it was completed one week before the top. Also make it a point to clean your joints while mortar is still setting up, once set its HARD and nearly impossible to remove.

We used a large canvas tarp to protect the floor and granite and make cleanup much easier.

Update: Feb. 9, 2009

Started installing wire mesh to help hold the the cultured stone in place. Put in the 1/2" plywood on top half to cover up the electrical conduit. Got the fireplace wired and plumbed. Rock woll is devil's cotton candy - it's a bitch! goes right through nitrile gloves - next time, double gloves.

Update 1: Jan 25, 2009

Added lintel to carry weight of the front wall, 2x2x1/4" cold rolled steel.

Added 2x4 layed flat on the top of brick to allow space for power and other crap that will go to tv. To be added later !

Anchors worked great! Except for one - why you see the PT wood in the upper corner. It was not compressing and I had put liquid naisl behind the 2x4, so i wanted to used one enxt ot it to press it down till i can try to fix it. These have the nut in the hole, so they tend to work better and have higher chance of gripping and not coming out - all meaning no cutting or excess threaded since, since the end goes into the wall. Liquid nails was insurance - overkill yes.

Blue ENT is 3/4", galvanized flex metal is 1 1/4". Blue boxes had to be modified slightly to accept the large 1 1/4" connectors. These will carry the low voltage signal cables, HDMI, compoents, tos-link, etc.

Next weekend: Rebrick lower half up to mantel, add in lintel across to carry weight of mantel, notch it to allow space for 3 tubes, face the top hald in 1/2" plywood, metal lathe and cultured stone!

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Update 0 - Jan 20, 2009: Retired wood burning fireplace converted to direct vent gas fireplace. One tube is intake, other exhaust.

They shoot up clay lined flue up to colinear adapter to colinear exhaust/intake. Ash box will be reused for

new gas line and electrical power. Previous owner had a gas log set so gas line was existing but will be replaced

with new plumbing.

Granite slab - heavy as SOB set on type N mortar

Going to run 2 boxes, one with male receptable to bring power up to recetable that will be behind tv and another

box to run all signal wires - may not need second box, just leave exposed conduit just below the level of the cultured stone.

Pain in the arse blower intall! NEVER AGAIN - get factory installed option. Lots of velcro, not enough room!

Remote temperature sensor, not predrilled like the manual says.

Easiest part of the job - adding blower rheostat and remove receiver.

What it all started out as:

During demolition and construction, mostly in winter, we would burn hundreds of pounds of wood per day. One person was literally on fire duty!

Wish I had picture of the ugly red brick venner that was on there. As you can see, no insulation in the walls!