1. Before installing the new fireplace insert, Nick must remove a chimney liner that was left over from an old pellet stove. On top of a snowy roof, he uses a screwdriver and metal snips to cut loose an old storm collar on top of the chimney. While Jake pushes from below, Nick grasps the liner and uses some elbow grease to wrestle it up and out of the chimney (figure A).2. In order to run an outside gas line directly into the cabin, Jake bores a hole through a mortar layer in the hearth wall using a power drill and then breaks through to the outside with a segment of rebar.
3. Jake instructs Nick to join segments of steel gas-line piping out through the hearth, wrapping along the cabin's exterior to the main gas line located outside. To join the pipes together, Nick brushes pipe dope onto the ends and then uses a pair of pipe wrenches to tighten on unions.
4. Nick wrenches a T-fitting onto the end of the first exterior pipe. This fitting will accept a pressure gauge for a leak test later. He continues wrenching pipes between unions, running along the sides of the cabin.
5. Because this cabin does not yet have a gas meter, Nick wrenches a cap onto the end of the plumbed gas pipe. Later, a natural gas company ties into the line when they install the meter. (Normally, the exterior gas line would be braced against the cabin with mounting brackets, but Nick leaves this step to the gas company when they install the meter).
6. Nick wrenches a pressure gauge onto the open end of the T-fitting connected earlier (figure B).7. Back inside the cabin, Nick and Jake build off the previously stubbed-in pipe. Nick plumbs in new pipes and unions around the back of the hearth and connects a yellow flex-pipe, which itself will connect to the fireplace unit.
8. After he positions the new unit within the hearth, he connects it to the gas line by wrenching on a shut-off valve between the flex pipe and a stem fitting underneath the unit (figure C).
9. Having turned the valve to the shut position, Nick uses a bicycle pump to test his plumbing for leaks. Pumping through the pressure gauge installed earlier, he floods the pipes with 15 PSI of air for one hour. Because no drop in pressure occurs, he knows the pipes can easily withstand the 1/2 pound of pressure that natural gas will provide. Later, the crew removes the gauge and caps the T-fitting for a tight seal.
10. With the gas pipes in working order, Nick returns to the roof to drop a new flexible steel liner down the chimney. Working directly below, Jake receives the end above the insert in the hearth and cinches the bottom of the liner to the insert's vent with a hose clamp.
11. Jake joins Nick on the roof to help connect a storm collar to the new chimney cap with a bead of caulk. Then, after cutting the liner to length with hand snips, Nick fits on the chimney cap with several screws.
12. To complete the new insert, Nick assembles the remaining components. First, he refers to the unit's instruction manual to properly assemble the included log set, air-supplying louvers and a clear glass panel on the front of the unit.
13. He completes the project by fitting on a black sheet metal surround that serves to cover the sides of the hearth (see image at top of page). Because of the unusual height of the hearth opening, the crew later fits a taller surround to close off the space above the unit.
Next, Nick tackles the complete installation of a new wood-burning stove.
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