Well I finally have the sheet metal back on my boiler after a long list of upgrades in getting ready for the 2009-2010 heating season! Thank you much to all the users of the forums here for the numerous amounts of advice directly and though reading back over old posts. This upgrade has been on my list since the moment I moved into our home 2 years ago. I think the original install of this unit was done as cheap as humanly possible and had just enough put into it to get it running (well not really it didn't run too well). I believe at one time upon seeing a picture of my unit on another post stoker-man mentioned something about Dr. Frankensein as doing the original install.
So here's how it broke down
-new domestic hot water coil gasket (with new welded stud as I broke one off)
-new taco air scoop and air vent (there was no air control on the system)
-new honeywell mixing valve for the domestic water (with bypass because I like a nice hot shower!!)
-new zone valve and return plumbed in for whatever future project comes my way (i think a garage heater)
-new barometric damper (unit was installed without one)
-new Honeywell R845A switching relay so both circulators aren't running at the same time when not needed anymore
-new Honeywell L6006A for outfire control
-upgraded all the wiring to proper BX
-tons of valves and unions to make servicing a heck of a lot easier
-setup to bring the returns in both sides of the boiler and space for 2 more returns when needed
-standardization of circulator flanges and piping (1 was 3/4" inch and 1 was 1" necked down pipe)
I purged the lines again one more time today and put all the sheet metal on and tied up all the loose ends. Hopefully this will not only have me running a lot more efficient but also make service and maintenance a lot easier in the years to come. I think this weekend I"m going to go and pick up somewhere from 5-6 tons of rice for the bin and then it's time to just sit back and enjoy the fall! Thanks again to the coal community!