The The Axeman has now left the building and resides with the new owner so I thought I would post a few more of the photos from the rebuild. Highlights of the items requiring attention:
1. Ash drawer Rollers needed some TLC and one needed replacement (there are bronze bushings in them and the rest of the linkage, I lubed all with Never Seize with nickel)
2. Area around coil had been eroded by previous leaks and owner filled in with high temp paint. Thoroughly cleaned and filled in with JB weld. Studs all were replaced (two broke off in the process and needed to be drilled and re-tapped). A note here, AA boilers use 1/8" pipe by 7/16-14 studs, make sure you get the right ones if you replace them.
3. Gear box and Fan bearing box were drained and refilled with fresh 5W
4. The cyclonic separator cone was inspected and resealed with 2200 *F furnace cement
5. The auger transfer head bronze bushings were replaced and the positioning collar re-adjusted for minimum play
6. New Belts, chain, and gearbox side sprocket
7. The ash drawer drive pawl was welded reshaped and hardened and the stop pawl was replaced due to excessive wear
8. The bushings in the ash drawer linkage arm were replaced.
9. Auger support roller bearings were cleaned and re-greased all were in servicable condition
10. Motor was replaced due to a bent shaft, although it was servicable enough to run the boiler for adjustment of fan position, belts and chain.
11. All 5 rubber mounting bushings replaced with new from AA
12. All wiring replaced with fresh BX, solenoid wires reworked with heat shrink for strain relief, and J box replaced.
13. And of course the entire boiler was stripped of paint, wire brushed and or sand blasted to remove loose rust and repainted in black, metal flake gray and high temp silver
Observe the proud look on the new owner's face as he contemplates a warm winter and domestic HW aplenty.