I'm On Fire wrote:Damn, C12 beat me to it.
I think he may have a draft inducer. Since you never cleaned the stove out or chimney I'm also going to assume you didn't disconnect the pipes. Are you positive the draft inducer is even doing anything anymore? Sure, the motor may turn the shaft but if the impeller still there to move the air? Ash plus moisture are not friends. The impeller on the draft inducer is very thin, I wouldn't be surprised if it's rotted out and gone.
As for smoke billowing out the doors and hopper, are the gaskets good?
It really makes me think you have no draft or a reverse draft. Do you have a manometer? Do you know what your draft is?
Im agreeing with ImOnFire here... clearly no or little draft is occurring, either impeller is broke off shaft or rotted OR the inducer could be fine but the pipe is clogged in front of or behind it so its not pulling any draft even though its spinning! You seriously CANNOT use this stove/chimney until you let her cool, take it all apart, get a nice hepa vac and start cleaning this baby completely! Now you can check everything out from grate gaskets to dollar bill tests to draft inducer to each hole in grate and inside grate after you remove it to behind interior baffle plate to pipe, etc. (i bet its NEVER been cleaned!)