I've finally been able to get some work done over the past week or two. I stripped two layers of paint and rust off the stoker using a combination of 3M stripping pads and wire brushes on an angle grinder as well as a little "black blast" grit blasting. I've got a little touch-up to do yet, but it's just about ready for paint. I picked up a quart of dark green hammertone Rust-o-leum, but I'm not sure I'll like it. Masterchem makes a "mid-green" Hammerite color that's rather more "vintage", but it's impossible to find so far except on-line. I don't want to use spray cans on something this big - it makes it hard to get even coverage without heavy/light areas - so liquid paint and my spray gun get the nod. Unfortunately that limits the Rust-o-leum color choices quite a bit compared to the spray can colors they offer.
Anyway, as I was stripping the stoker, I became more and more impressed at how well it's made and how THICK all the sheet metal is!! I think the hopper lid is at least 16ga. (.065) material and maybe even 15 (.074) or 14ga. (.083)! It's HEAVY! Everything on the stoker is stamped or formed, sealed, gasketed, etc. Shoot, even the 1/2-13 nuts used to hold the gearbox to the auger are works of art - machined with a top and a bottom side, heavy, FIT the wrench, and have a larger hex size than I'm used to for 1/2" nuts. I can't imagine what it would cost to build today. Conversely, with modern CNC lasers, press brakes, and turret press and welding equipment, a "modern" stoker could be made at a decent price but certainly would lack the style and art-deco mojo of the originals.
I'll get some pics of the before-paint and after-paint states, as well as all the other little details as I put it back together. Then I'll need to strip the EFM boiler of it's coating of rust and weld in the patch/blank-off plate for the DHW coil and paint it with a coat of aluminum paint. Then I have the base to fabricate, plumbing, controls, chimney...... I'll just remind myself that this is nothing compared to Greg's little house project!