Isokern Magnum 86072-60 User manual

Isokern ® Magnum ® Fireplace
and DM Chimney System
Installation, Operation and Owner’s Manual
Magnum Model 86072, 60 & 72
A Product of Earthcore
THIS FIREPLACE IS DESIGNED FOR USE WITH
SOLID WOOD LOGS, PLUMBED PROPANE (LP) OR
NATURAL GAS (NG), ONLY
SBCCI NO. 9626 NYC-MEA 241-90-E
ICC Report NO. ESR-2316 LA RR NO. 25483
IBC 2006, IRC 2006, IMC 2006 Issued: September, 2012
Revision:
INTERTEK TESTING SERVICES REPORT NO. 3082504-T1
© 2007 Earthcore Industries, L.L.C.
THIS MANUAL CAN ONLY BE REPRODUCED IN ITS ENTIRETY
Important: This manual contains assembly rules, installation steps, guidelines, use and maintenance
instructions for the Magnum 86072 Series replace and the DM chimney system. This manual must become
the property of and be reviewed by all current and future users of this product. It is the responsibility of
the general contractor and the installer of this product to ensure that the instructions in this manual are
followed exactly and, further that any allowed gas log appliance used in this product be installed in strict
accordance with NFPA 58, NFPA 54/ANSI Z223.1 and the gas log manufacturer’s explicit installation, sizing
and operation instructions. It is the responsibility of the general contractor to provide adequate clearances
from all rebox surfaces as specied in this manual.
INSTALLER: Leave this manual with the appliance
CONSUMER: Retain this manual for future reference
Be Sure to Read Entire Manual Before Beginning Construction.
Contents of this manual may change without prior notication.
WARNING: If the information in this manual is not followed exactly, a re or explosion may result
causing property damage, personal injury or loss of life.

TABLE OF CONTENTS
General Information .......................................................................................................................................
Intended Use Statement ......................................................................................................................................
Safety Instructions ..............................................................................................................................................
Warnock-Hersey Listing Label ...........................................................................................................................
Assembled Firebox & Smoke Dome Dimensions ..............................................................................................
Component List & Dimensions ..........................................................................................................................
Required Clearance to Combustibles .................................................................................................................
Rough Framing Dimensions & Corner Location Layout ...................................................................................
Access Modication ...........................................................................................................................................
Firebrick Installation ..........................................................................................................................................
Flush Wall Finish Detail .....................................................................................................................................
Assembly Instructions - 86072-60 .......................................................................................................................
Assembly Instructions - 86072-72 .......................................................................................................................
DM Chimney System - 86072 ............................................................................................................................
Required Clearances (When sheathing protrudes beyond front of rebox) .......................................................
Required Clearance to Combustible Framing ....................................................................................................
Required Clearances to Insulation and Vapor Barriers ......................................................................................
Flush Wall Fire Brick Finish Detail ...................................................................................................................
Flush Wall Brick Finish Detail ............................................................................................................................
Interior Masonry Veneer Fireplace Finishes & Clearances...................................................................
Masonry Veneer Construction Details ..................................................................................................
Non Combustible Finished Facing Requirements & Clearance to Combustible Trim .......................................
Concrete Support ...............................................................................................................................................
DM Chimney System ........................................................................................................................................
General Information ............................................................................................................................
Component List & Dimensions.............................................................................................................
Component Weights .............................................................................................................................
DM Installation ...................................................................................................................................
Lateral Support ....................................................................................................................................
Offset Block .........................................................................................................................................
Brick Ledge ..........................................................................................................................................
Brick Ledge Installation .......................................................................................................................
Brick Ledge Load Capacity ..................................................................................................................
Crown Caps ..........................................................................................................................................
Chimney Height Requirements ............................................................................................................................
Structural Information ..........................................................................................................................
Common Chimney Terminations .........................................................................................................
Class “A” Metal Flue .........................................................................................................................................
Summary .............................................................................................................................................................
Registration .........................................................................................................................................................
3
4
5
6
7
8
9
10
11
12
13
14-18
19-23
24
25
26
27
28
29
30
31
32
33
34-46
34
35
36
37
38-39
40-42
43
44
45
46
47
48
49
50
51-52
53
3

General Information
The Magnum 86072 Series replace and DM chimney
system is a prefabricated, refractory modular replace and
chimney system designed for eld assembly. The system
consists of interlocking precast parts which are glued together
with a masonry adhesive.
The parts of the Magnum 86072 Series replace and
DM chimney system are precast using a proprietary mixture of
volcanic pumice aggregate and cement. It includes all the parts
necessary for assembly of a complete rebox, smoke dome and
chimney system.
Each Magnum 86072 precast replace component is
designed for a specic part of the replace such that only one
means for assembly is possible.
The rebox and smoke dome are designed to be tted
with a traditional cast iron, poker-style throat damper. However,
in-line or chimney top dampers are options.
The Magnum 86072 Series replace requires a
standard refractory re brick liner be applied to the interior
of the rebox. Fire brick must be a minimum thickness of one
and one-eighth inch (1-1/8”) on the oor and back walls. A
minimum four inch (4”) re brick must be applied to the side
walls.
The Magnum 86072 Series replace is available in
two sizes: sixty inch (60”) and seventy-two inch (72”).
All units have a thirty-eight inch (38”) rough opening
height before re brick. The only parts which differ among the
available sizes are width related pieces. All units use the same
side wall pieces.
The DM chimney system is a dual module refractory
chimney system. The basic chimney consists of an outer casing
block and an inner liner. Two (2) ues are necessary on the 86072
model without a mechanical drafting system. It is acceptable
to use mechanical draft systems, if the venting companies
do the engineering calculations and make the necessary
recommendations for fan size and ue vent diameter following
the guidelines of NFPA 211/2006, pg. 211-13. Installation
of such systems must also follow the mechanical drafting
company’s explicit installation and operation instructions.
“Smoke free” operation is not warranted nor is the
manufacturer responsible for inadequate system draft caused
by mechanical systems, general construction conditions,
inadequate chimney heights, adverse wind conditions or
any unusual environmental conditions or factors beyond the
manufacturer’s control. The chimney components are eld
assembled using Earthcore Mortar to glue the components
together.
The DM chimney system also includes an offset
chimney block component, used to create offsets to the vertical
run of the chimney. A brickledge component is available,
designed to support chimney top brick veneer nishes.
Prefabricated masonry chimney termination caps are also
available.
The various Magnum 86072 Series replace and
DM chimney components will be described and illustrated in
the following pages. Close attention should be paid to each
component group’s specications and installation requirements
as described in this manual.
Maximum overall height for the Magnum 86072
Series and DM chimney system for an indoor application is
22’-0” without additional structural support. This restriction
does not apply for metal chimney systems.
4

Intended Use Statement
WARNING: This replace has not been tested for use with
doors. To reduce the risk of re or injury, do not install doors.
Operable doors are acceptable and if doors are required by the
local authority having jurisdiction, then doors must be kept
in the fully open position when the replace is in operation.
Isokern does not limit the use of replace screens.
Note: Do not scale drawings. Illustrations in this manual are not
to scale and are intended to show “typical” installations.
Nominal dimensions are given for design and framing
reference only, since actual installations may vary due to
job specic design preferences. Always maintain the stated
minimum clearances to combustible materials. Do not violate
any specic installation requirements.
The Magnum 86072 Series replace and DM chimney
system is tested and listed by Warnock Hersey (Intertek Testing
Service) - Report No. 3082504-T1 - to UL 127, and UL
103HT.
Magnum 86072 Series replace systems are also
designed for installation in accordance with the National Fire
Protection Association Standard for chimneys, replaces, vents
and Solid Fuel-Burning Appliances (NFPA 211).
5
Intended Product Use Statement:
The Magnum 86072 Series replace and DM chimney
systems are intended to burn solid wood fuel, propane or natural
gas.
Note:
Installation of a gas pipe must comply with the Standard for
Decorative Gas Appliances for Installation in Vented Fireplaces,
ANSI Z21.60.
This replace is not designed to sit directly on a
combustible oor system. The Fire-Lite application of the
Magnum 86072 Series replace is an engineered system and
designed to be built upon a combustible oor system. The Fire-
Lite will also require a design that will support the total weight
of the Isokern replace and chimney system. The FTF-13 or
equivalent chimney system only must be used with the Fire-
Lite application. Contact the Technical Department at 800-642-
2920 for details.
This replace is intended for use as a supplemental
heat source only and is not intended for heavy use as a primary
heating system.
Overring, abusive burning or mistreatment will void
any claims (eg. burning construction debris or other highly
ammable material; tossing, kicking or otherwise forcing logs
into the rebox).
Magnum 86072 Series replaces and DM chimney
systems are conventional indoor or outdoor replaces designed
to appear like traditional masonry replaces. Magnum 86072
Series replace and DM chimney system units are intended
for installation in residential homes and other buildings of
conventional construction.
Note: The local authority having code jurisdiction should be
consulted before installation to determine the need to obtain a
permit.
Important areas of concern with the installation of these
replaces are: construction of proper load bearing foundation
and concrete support slab; code required hearth extension
substrates and supports; proper assembly of components;
clearance to combustible materials; height of chimney; and,
techniques employed in applying nishing materials to the
replace opening and hearth extension.
Each of these important topics will be covered in detail
throughout this manual. Installation personnel must give special
attention to each topic as the installation progresses.
All work performed on, near and adjoining the replace
and chimney installation must meet or exceed the specications
and requirements in this manual and the prevailing local
building code.
Subsequent renovations, additions of cabinets and
storage spaces in the enclosure surrounding the replace are
also limited to the specications in this manual and to the
prevailing local building code.
Isokern is not responsible for other construction work
around the replace unit.

Safety Instructions
1. Before starting the Magnum 86072 Series replace and
DM chimney installation, read these installation instructions
carefully to be sure you understand them completely. Failure
to follow them could cause replace malfunction resulting in
serious injury or property damage.
2. Always check local building codes governing replaces and
replace installations. The Magnum 86072 Series replace and
DM chimney installation must comply with all local, regional,
state and national codes and regulations.
3. Magnum 86072 Series replace and DM chimney systems
are intended for use in any application where a traditional
masonry type replace would apply. The chimney system must
always vent vertically to the outside of the building.
4. Creosote and soot formation and the need for removal: When
wood is burned slowly, it produces tar and other organic vapors
which combine with expelled moisture to form creosote. The
creosote vapors condense in the relatively cool chimney ue of
a slow burning re. As a result, creosote residue accumulates
on the ue lining. When ignited this creosote makes an
extremely hot re.
Because of creosote and soot buildup it is necessary
to inspect and clean the replace and chimney prior to use
and periodically during the heating season. Cleaning of the
replace and the chimney system should be done annually at
a minimum. In colder climates, chimney cleaning may need to
be done periodically throughout the heating season.
5. Before servicing, allow the replace to cool. Always shut
off any electricity or gas to the replace while working on it.
6. Use only solid fuel or natural or LP gas log sets in this
unit. Do not use articial wax based logs, chemical chimney
cleaners or ame colorants in this replace.
7. Never use gasoline, kerosene, gasoline-type lantern fuel,
charcoal lighter uid, or similar liquids to start or “freshen up”
a re in this replace. Keep all ammable liquids at a safe
distance from the replace.
8. Always keep the ue damper open when heat is present in
the replace.
9. Do not use a replace insert or any other product not
specied for use with the Magnum 86072 Series replace and
DM chimney systems unless written authorization is given by
Earthcore. Failure to heed this warning may cause a re hazard
and will void the warranty.
10. This replace is not intended to heat an entire home or
to be used as a primary heat source. It is designed to ensure
homeowner comfort by providing supplemental heat to the
room.
11. Always ensure that an adequate supply of replacement
combustion air from the outside of the house is accessible to
the re to support normal combustion. Fireplaces consume
large volumes of air during the normal ring process.
In the event the home is tightly sealed and has modern
energy efcient features, the optional combustion air supply
kits may not provide all the air required to support combustion
and the proper ow of combustion gases up the chimney.
The manufacturer is not responsible for any smoking
or related problems that may result from the lack of adequate
air supply owing into the house. It is the responsibility of the
builder/contractor to ensure that adequate air supply has been
provided for the replace.
12. “Smoke free” operation is not warranted nor is the
manufacturer responsible for inadequate system draft caused
by mechanical systems, general construction conditions,
inadequate chimney heights, adverse wind conditions or
any unusual environmental conditions or factors beyond the
manufacturer’s control.
Caution: When used with the Magnum 86072 Series replace
system, all gas log sets must be operated with the damper
clamped in the fully open position. This includes unlisted
“vent free” log sets. Only listed “vent free” log sets may be
operated with the damper in the closed position.
13. When in doubt about a component’s usability - has visible
or suspected physical damage - consult your Isokern distributor
or authorized Isokern representative for advice.
14. Modication to Magnum 86072components not mentioned
in this manual may void claims, listings and approvals and
could result in an unsafe and potentially dangerous installation.
Alterations to the Magnum 86072 rebox are allowed
with prior written approval and instructions from Earthcore
Industries, LLC. The installer indemnies the manufacturer of
all claims and under no circumstances will manufacturer be
liable for consequential, incidental, indirect, punitive or other
damages of any kind or nature, whether foreseeable or not,
based on any claim by any party as to the modications of the
Isokern replaces.
15. Keep all insulation, vapor barriers, “house wrap”
paper and other insulating type membranes and products,
including berglass, cellulose and other insulation,
(anything that carries an “R” rating) a minimum of three
inches (3”) away from all rebox and chimney surfaces.
Exception:
If insulation is used in walls surrounding the replace,
insulation may be installed behind sheathing of gypsom board,
plywood, particle board or other material on the side facing
the Isokern. The facing material cannot be within 1 1/2” to the
replace sidewalls.
WARNING: Do not pack required air spaces with insulation
or other materials.
16. Never leave children unattended when there is a re
burning in the replace.
17. Burning some fuels (such as charcoal) can be hazardous due
to the possibility of producing carbon monoxide, a colorless,
odorless gas. Early signs of carbon monoxide poisoning
resemble u symptoms, including headaches, dizziness or
nausea. Over exposure to carbon monoxide can lead to illness
and death. It is strongly recommended to install smoke and
carbon monoxide alarm / detector devices wherever replaces
are in use.
6

Warnock Hersey Listing Label
- Facsimile -
7
FIGURE 1
Isokern Fireplace and Chimney Systems are tested and listed to UL standards: UL 127, ULC S610, and UL 103HT. The listing label
shown in Figure 1 above outlines the listed clearances to combustibles and indicates that the units are suitable for use with solid fuel
or listed gas appliances. Refer to the manufacturer’s installation manual for detailed description of clearances to combustibles and all
other installation information.
A metal listing label similar to that shown above is afxed to each Magnum 86072 Series replace. Do not remove the listing label
from the Magnum 86072 Series replace.
Prior to beginning installation, contact your local building ofcial to determine the need to obtain a permit.

8
Assembled Firebox Dimensions - Model 86072
Model
Minimum Framing
60”
76 1/2” W x 87 1/2” H x 29½” 2650 lbs.
72”
B
28”
28”
D
41”
41”
H
25 ¼”
25 ¼”
I
4 3/4”
4 3/4”
J
5”
5”
K
8”
8”
TOP PLATE
(TWO REQUIRED)
Part
No.:
M77
Fireplace
Size:
60” W
Quantity:
2
25 ¼”
10 3/4”
4 ¾”
N
M
Right SectionFront Elevation
Top Plan View
Plan Section
F
69 3/4”
57 1/4”
M
14 1/2”
14 1/2”
N
10 3/4”
10 3/4”
32 3/4”
A
85 1/2 ”
73 1/2”
C
85 3/4 ”
85 3/4”
E
69”
G
55 1/2“
65 1/2”
C
D
HG
I
K
F
E
E
B
A
J
B
M77 72” W2
81 1/4”
Weight
88 1/2” W x 87 1/2” H x 29½” 2950 lbs.
O
55 1/2”
65 1/2”
O

Component List & Dimensions 86072
9
Isokern reserves the right to make changes at any time, without notice in design, materials, specications and also to
discontinue styles and products. Please call 1-800-642-2920 for an Isokern dealer near you.
42 3/4"
Base Plate
Part FireplaceQuantity:
No:Size:
M91 60 2
M91 72 2
Top Medium
Part FireplaceQuantity:
No:Size:
11 60 2
11 72 2
Top Large
Part FireplaceQuantity:
No:Size:
13 60 6
13 72 6
Top Sloping
Part FireplaceQuantity:
No:Size:
34 60 4
34 72 4
Backwall
Part FireplaceQuantity:
No:Size:
M67 60 8
M67 72 8
Damper Support (Left)
Part FireplaceQuantity:
No:Size:
M94L 60 1
M94L 72 1
Damper Support (Right)
Part FireplaceQuantity:
No:Size:
M94R 60 1
M94R 72 1
43"
28"
"61
4"
"61
4"
52 3/4"
3"
25 1/4"
"61
40"
"2/19
5"
Damper Front & Back
Part FireplaceQuantity:
No:Size:
M69 60 4
M69 72 4

0” CLEARANCE
1 1/2"
No Combustible
Underpinnings
33”
0” CLEARANCE
The Magnum 86072 Series replace and the DM
chimney system is tested and listed for installation with “clearance
to combustibles” as follows:
All DM 44 and 54 chimney components require 0”
clearance. (Figure 2).
The Magnum 86072 Series rebox side walls and back
wall require 1-1/2” clearance. (Figure 3)
The smoke dome front wall requires 0” clearance.
Note: “Combustibles” are dened as “normal construction
materials” and are considered to be: wood framing materials,
particle board, mill board, plywood sub-ooring, plywood
paneling and wood ooring.
Sheathing materials, such as plywood, particle board
and drywall may cover the smoke dome front at 0” clearance.
All combustible sheathing materials that protrude beyond front
of rebox must be held 9” away from the sides of the rebox
opening and 24” above the top of the rebox opening. Drywall
must be cut 9” back from the rebox opening sides and 24” above
the top of the opening.
Keep all insulation, vapor barriers, “house wrap” paper and
other insulating type membranes and products, including
berglass, cellulose and other insulation, (anything that
carries an “R” rating) a minimum of three inches (3”) away
from all rebox and chimney surfaces. See exception.
Exception:
If insulation is used in walls surrounding the replace,
insulation may be installed behind sheathing of gypsom board,
plywood, particle board or other material on the side facing
the Isokern. The facing material cannot be within 1 1/2” to the
replace sidewalls.
Notes: A. The Magnum 86072 Series replace must sit upon a
concrete support slab designed to bear the total installed weight
of the replace and DM chimney system. These support slabs
can have no wood underpinnings. (Figure 3)
B. Concrete support slabs for Magnum 86072 Series
replaces must provide the noncombustible hearth extension
substrate needed to support the code required noncombustible
hearth extension nish materials. (Figures 2 and 3)
C. All Magnum 86072 Series replaces shall have
hearth extensions of approved noncombustible material such as
brick, tile, or stone that is properly supported and with no com-
bustible material against the underside thereof. Wooden forms
used during the construction of hearths and hearth extensions
must be removed when the construction is complete.
D. If a raised replace oor and raised hearth exten-
sion are preferred, the raised underlying structure must be built
of noncombustible material, be structurally designed to hold
the weight of the replace and chimney system and must sit on
noncombustible substrate.
Required Clearance to Combustibles
10
FIGURE 2
FIGURE 3

B
B
A
D
C
A
FRAMED OP'G.
MINIMUM
FRAMED OPENING
2'-5 1/2"
11
Rough Framing Dimensions
Corner Location Layout
Rough Framing Dimensions
Model Width Height Depth
A B C
Model 60 76.5” 87.5” 29.5”
Model 72 88.5” 87.5” 29.5”
Notes:
A. “B” includes the Magnum 86072” 3” thick base plate. “B” is reduced
by 3” if the base plate is eliminated to create a “ush hearth”.
B. “Raised hearth” requires additional rough opening height at “B”
equal to the height of the raised hearth detail.
C. Rough framing dimension for width “A” allows for the required
1-1/2” clearance at the sides of the Magnum 86072 Series replace.
D. Rough framing dimension for depth allows for the required 1-1/2”
clearance at the back of the Magnum 86072 Series replace.
The following chart of dimensions is intended to aid in the positioning of
an Magnum 86072 Series 86072 replace in a corner condition
where the DM chimney must turn 45° degrees to align with overhead
framing.
Firebox A B C D
Model 60 73 1/2” 39” 53 1/2” 102 1/2”
Model 72 85 1/2” 45” 62” 111”
To turn ue 45°, rst set one offset block on the rebox so that
the chimney offsets 3” toward the back of the rebox. (Figure 5)
Set a DM outer casing onto this offset block so that the outer
casing is at 45° to the rebox and square to the overhead framing system.
Run the vertical DM chimney through the overhead framing.
More offset blocks can be used - if necessary to align with
overhead framing - before running the vertical DM chimney outer casing
and liner.
Note: Support the third offset down to footings and at each third offset
block thereafter.
FIGURE 4
FIGURE 5

12
Assembly Instructions - Access Modication
Through-Wall Accesses:
1. Combustion Air Inlet: Combustion air inlet kits though not required
by Earthcore with other ventilating appliances installed.
Check local codes for combustion air inlet requirements.
The following is a general representation of a generic
combustion air kit and not a requirement of Earthcore Industries,
LLC. Local building codes prevail and should be checked before
installation.
Generic replace combustion air kits typically consist of a
sliding stainless steel access door afxed to a three inch (3”) or four
inch (4”) diameter stainless steel sleeve approximately twelve inches
(12”) long. An exterior vent with dress plate, weather hood and rodent
prevention screen of a maximum one-quarter inch (1/4”) wire mesh
completes the kit. (Figure 5)
The access door is tted into the nished re brick lining at the
interior sidewall of the Magnum 86072 rebox. The twelve inch (12”)
long sleeve can be introduced into the rebox side wall by core drilling
an appropriately sized hole at the selected rebox location. Keep the
top of the access hole no more than six inches (6”) above the nished
rebrick oor. The hole size should allow for a one-quarter inch (1/4”)
mortar joint around the air access sleeve for heat expansion.
The sleeve passes through the rebox wall and must be
connected to metal pipe (by other) - either exible or rigid - that leads
to the source for outside combustion air, as directly as possible from the
Magnum 86072 Series replace (Few to no bends) with a maximum
length of sixty feet (60’).
WARNING: Do not use combustible duct material. Avoid installing
a combustion air inlet where the opening could be blocked by snow,
bushes or other obstacles. Air inlet must terminate a minimum of three
feet below the chimney cap level. Air inlet ducts shall not terminate in
attic spaces.
2. Gas Line Feed: For a replace having the provision for installation of
a gas pipe, the provision is intended only for connection to a decorative
gas appliance.
CAUTION: When using the decorative appliance, the replace damper
must be set in the fully open position. Gas line for gas log sets used in
the Isokern rebox can be routed through the side wall, by drilling an
appropriately sized hole using a masonry drill bit (Figure 7).
3. Electrical Line Feed can be routed through the Magnum 86072 rebox
side walls by drilling an appropriately sized hole using a masonry drill
bit (Figure 6). Be sure to follow the gas log Appliance Manufacturer’s
explicit electrical line connection instructions for vented masonry
replace installations.
Gas line and electric line must be fed through separate access holes.
CAUTION: All access holes must be grouted with mortar – after line
or conduit feed - to seal any gaps or cracks around line feed conduits
(Figure 7).
FIGURE 5
AROUND CONDUIT WITH
NOTE: FILL ANY GAPS
MORTAR.
NON-COMBUSTIBLE).
T
YPICAL PLACEMENT OF
(S
EE DETAIL BELOW).
SUPPLY AIR VENTILATION
(IF REQUIRED BY CODE).
G
AS OR ELECTRIC CONDUIT
FIRE BRICK SIDE
CONDUIT
GAS OR ELECTRIC
EXTERIOR
EXTERIOR AIR VENT
WITH DRESS PLATE.
WALL
FLEX DUCT TO FIREPLACE
FIREBOX, (ALL PARTS
FIGURE 6
FIGURE 7

13
Assembly Instructions - Fire Brick Installation
Fire Brick Installation:
The manufacturer requires that the Magnum 86072
reboxes be lined with a minimum one and one-eighth (1-1/8”)
thick re brick on the back and oor of the rebox and four-inch
(4”) on the side walls. Thicker re brick may be used as an option.
The pattern for the re brick lining is an owner option. Standard N
or S type brick mortar is suitable mortar for the replace.
Fire brick mortar needs to be suitable to both adhere the
re brick to the inside of the rebox and to create the nished face
joints of the brick work. Based on a history of eld applications and
experience, a suitable mortar would be as follows:
Mix:
* 1/2 bag EC mortar or Six parts masonry mortar (S or N type)
* Six parts sand
* One part Fire Clay (optional)
* Water to a sticky, toothpaste consistancy
Because of different climates, the use of good masonry practices for
your area should also be considered.
It takes about 50 lbs. of mortar mix (dry measure) to re-brick line
a Magnum 86072 replace.
Installation Instructions:
Installation Instructions:
1. Wet mop the inside of the replace with a damp sponge
to remove dust and loose particles from the interior before re-
bricking.
HINT: Dip each rebrick into water before applying.
2. Face joint dimensions of 1/4” to 3/8” in the brick work
is recommended and has the best appearance. Other face joint
dimensions are acceptable however smaller joints may not leave
room for heat expansion of re brick.
3. Start the re brick at the front edge of the oor of the
Isokern rebox, proceeding inward toward the back. Let the oor
brick gap approximately 1/2” off the back wall and side walls. This
air space allows heat expansion of the re brick and is to be left
empty of mortar. (Figures 8 & 10)
4. Next, apply re brick to the back wall of the unit. The
back wall re brick covers the 1/2” expansion gap left at the brick
oor along the back wall of the rebox. (Figure 9)
5. Set the side wall re brick by starting at the front edge
of the unit’s side wall and working inward toward the back wall
re brick. The side wall re brick, when completed, covers the 1/2”
expansion gaps where both the oor re brick and the back wall re
brick were held off the units side walls. (Figure 10)
All required through-wall accesses (gas and electrical line
feeds and combustion air supply access holes) should be drilled
before the required re brick lining is installed.
Isokern makes no claims as to the performance of re
brick or re brick mortar(s). It is typical for heat stress cracks
to appear in the re bricks in wood burning replaces.
FIGURE 8
FIGURE 9
FIGURE 10
FIRE BRICK
FLOOR AND
BACK WALL
(BUILT FIRST)
EXPANSION
1/2" GAP
FIRE BRICK FLOOR
(BUILT FIRST)
EXPANSION
1/2" GAP
(NO GAPS)
4” Firebrick
Required on
Side Walls

1 1/2”
MIN
1 1/2”
MIN
24”
MIN
Damper Beam
Behind Noncombustible
Facing Material
Drywall Flush With
Firebox Front With 1 1/2”
Clearance To Framing
Framing Protrudes Past
Firebox Front
9”
14
Flush Wall Finish Detail
Magnum 86072 Series replaces are designed to be installed so that the rough front face of the rebox and damper beam
project into the room approximately one-half inch (1/2”) beyond the face of the rough framing members that create the room’s wall
surface.
Noncombustible facing material must span framing members above the replace opening for drywall to keep the required
twenty four inches (24”) above the rebox opening top; It is after this noncombustible material that framing members can be placed
as shown above. Nine inches (9”) on each side of the rebox opening is also required to be covered in noncombustible material.
(Figure 11).
Important: Do not build a frame wall in front of the Magnum 86072 rebox and damper beam. (Figure 12)
FIGURE 11 FIGURE 12

Assembly Instructions - 86072-60
The Magnum 86072 - 60 is a custom unit made of standard
parts that are cut and tted together in the eld. The following
cut and assembly instructions identify the parts by name and by
part number, the quantity required, the eld cut dimensions for
each modied component and the placement of each part in the
assembly.
Note: At all component placement, be sure to mortar all contact
surfaces with Earthcore Mortar. Check for complete sealing of
each contact joint while assembly progresses
Step 1: Base plate, part # 91, two required; All require eld cutting.
Set the un-cut # 91 base plate components on an appropriate
masonry foundation. Cut one base plate to 30 1/2”. (Figure 13) Set
the two pieces so that the line of the grouping is a butt joint. (Figure
14). Set the cut # 91 pieces into place. This makes for square ends.
The overall length of the base plate assembly should measure 73-
1/2” and 28" deep.
Step 2: Side wall, part # 90, eight pieces required, used “as is”. The
re box side wall components are used without modication. The
side wall pieces stack four high on both the left and right hand ends
of the base plate arrangement (Figure 15)
The stack of four re box side wall components will be
assembled in conjunction with the rebox back wall components
described in the following steps.
Step 3: Back wall, part # 67, eight pieces required, to be “eld
modied”. Cut the tongue off one end of each of the four # 67 back
wall components as shown. After cutting, four of these, cut pieces
should measure 38 1/2” from the cut end to the shoulder of the un-
altered end.(Figure 16)
The other four cut pieces should measure 22 1/4” from the
cut end to the shoulder of the unaltered end. (Figure 17)
Step 4: Build the Magnum 86072 - 60 rebox by setting a 38 1/2”
# 67 back wall (from step 3) on the base plate with it’s tongue end
interlocked into the rebox side wall at the end of the baseplate.
The square cut end of this a 38-1/2” # 67 back wall
component sits ush with the back of the base plate with its cut end
past the centerline in the base plate arrangement (Figure 18).
Next set the 22-1/4” cut # 67 piece so that its tongue
end interlocks with the side wall component at the opposite end
of the base plate. The square cut end of the 22-1/4” # 67 should
make a snug butt joint with the square cut end of the 38-1/2” # 67
component (Figure 19).
15
FIGURE 13
DISCARD
DISCARD
43”
DISCARD
73 ½
38 1/2“
22 1/4”
30 1/2”
30 1/2”
28”
FIGURE 14
FIGURE 15
FIGURE 16
FIGURE 17
FIGURE 18

16
Assembly Instructions - 86072 - 60
Step 5: Continue stacking the remaining three courses of back
wall. Be sure to reverse the positions of the 38-1/2” # 67 and
the 22-1/4” # 67 in each successive course. In this way, the
butt joint where the two # 67 components meet are staggered
from course to course. The overall width dimension at the
back of the rebox should be 73-1/2” including the sidewalls.
(Figure 20).
Step 6: Steel angle 4” x 6” x 5/16”, one required, 73-1/2” long
to span rebox opening.
This steel angle sits on top of the uppermost side wall
component with the four inch leg in the horizontal position.
To avoid a thickness problem with the placement of the
steel angle it is necessary to cut a notch in the top Side wall
component where the angle is to sit. This notch should be cut
approximately 5/16” deep. The notch should start at the front
face of the side wall component (at both the left and right hand
walls) and run to a point 4” back toward the rebox (Figure
21).
The steel angle sits in this notch. The six inch leg of
the steel angle is in the vertical position and is to be located in
alignment with the front of the rebox. The ends of the steel
angle should not protrude beyond the outer rebox side walls
(Figure 21). Mortar between the steel and the notch in the top
of the side wall is not needed.
Step 7: Damper support (front & rear), Part # 69, four required,
to be eld cut to t.
Bevel cut one end of each of two # 69 damper
supports to 35-1/2” in length from the long point of the bevel
cut to the un-cut square end. (Figure 22). The long point of the
bevel cut is to be at the top of the damper Support
For best results a 15˚ bevel angle is suggested.
Step 8: Bevel cut one end each of two # 69 damper supports
to 38” with the long point of the bevel at the bottom of the
damper support. The bevel angle must be at the same angle –
in this case, 15 degrees - to match with the bevel angle of the
other damper supports already cut in Step 7 (Figure 23).
Step 9: Set the cut damper supports along the front and along
the rear of the rebox using one of each of the cut pieces (one
with the long point at the top of the piece and one with the long
point at the bottom of the piece) together as pairs.
Note: Be sure to put Earthcore Mortar on the contact surfaces
of the vertical joints where the components connect. Look
for some mortar to squeeze out along the joints of all contact
surfaces as a sign that the joint is thoroughly sealed with the
approved mortar. Fill any and all gaps in the assembly, as
necessary, with the approved mortar.
FIGURE 19
73 ½”
38””
35 1/2”
DISCARD
DISCARD
15 DEG. ANGLE
4”
5/16”
FIGURE 20
FIGURE 21
FIGURE 22
FIGURE 23

73 ½”
23 3/4”
DISCARD
49 3/4”
DISCARD
# 13
# 13
23 3/4”49 3/4”
73 ½”
17
Assembly Instructions - 86072-60
The damper support pair at the front of the rebox opening
will be mortared together and set into the steel angle from Step 6
(Figure 24).
Since the inside corner of the steel angle is rounded, it is a
good idea to round the bottom front corner of the damper support to
match the steel.
With the bevel cut ends of the damper support pairs meeting
at the middle of the rebox, the bevel joint should be an even and
good t. The damper supports overall installed length should be 73-
1/2”. (Figure 24)
Note: Do not join the damper supports with a butt joint. The bevel
joint discussed above is the REQUIRED type of joint for the
damper support.
The bevel angle of 15˚ degrees is a convenient angle and
is given as a suggested angle. The angle of the bevel cut could be
greater, just so the bevel cut in each damper support joining pair is
the same angle in order to have a good t at the joint.
Please consult your local sales representative for the
appropriate damper systems for Magnum 86072-60 Series.
Step 10: Damper support (left), part # 94L and damper support
(right), part # 94R, one each required. To be used “as is”.Set the
damper support (left) and the damper support (right) into place on
top of the rebox side walls in between the front and rear damper
supports.
Each of the damper supports, right and left, is designed
specically for its own side of the unit. When properly set, each
damper plate side piece sits ush with the outside face of the rebox
side wall. The interior bottom edge of the damper support end pieces
aligns with the angle of the interior of the rebox side wall (Figure
25).
For the Magnum 86072 - 60 the smoke dome components
stack two tiers high giving a smoke dome of approximately 32” in
height.
Step 11: Smoke dome medium, part 11, two required, to be “eld
modied”; smoke dome large, part 13, six required, to be “eld
modied”; smoke dome top sloping, part 34, four required, to be
used “as is”.
Begin building the Magnum 86072 - 60 Fireplace smoke
dome by cutting the haunch off of one end of each of the two smoke
dome large components, part 13. After cutting the bottom length
of the piece will be 49 3/4”". (Figure 26) When cutting the haunch
off be sure to follow the angle of the sloping end in order to get the
proper slope angle to the cut.
Step 12: Cut one end of two of the smoke dome top large, part 13,
components at an angle parallel to the opposite end of the piece. The
bottom length of the cut piece should measure 23 3/4 ” (Figure 27)
.
Note: Be sure to put Earthcore Mortar on the contact surfaces of the
vertical joints where the components connect. Look for some mortar
to squeeze out along the joints of all contact surfaces as a sign that
the joint is thoroughly sealed with the approved mortar. Fill any and
all gaps in the assembly, as necessary, with the approved mortar.
FIGURE 24
FIGURE 25
FIGURE 26
FIGURE 27
FIGURE 28

39 3/4”
DISCARD
73 1/2”
2 ¾”
# 13
23 3/4”
DISCARD
# 11
# 13
# 13
# 13
# 11
18
Step 13: Place one modied smoke dome large piece (haunch
cut off and a bottom length of 49-3/4" together with another
of the smoke dome large pieces that was angle cut to 23 3/4"
bottom length and parallel angle) together on the damper
support and ush with the back wall of the rebox so that the
two smoke dome pieces meet along their eld modied cut line.
The overall length of the two joined smoke dome
pieces should be 73-1/2". (Figure 28)
Step 14: Repeat STEP 13 on the front damper support. Set the
front smoke dome components 2-3/4" back from the front face
of the front damper support (Figure 29).
Step 15: Fit the top sloping smoke dome side wall components,
part 34, in place between the front and back smoke dome
arrangements at each end of the smoke dome. (Figure 30)
Step 16: Continue building the Magnum 86072 - 60 replace
smoke dome by cutting two of the smoke dome large pieces,
part 13, to a bottom length dimension of 39 3/4”. The slope
angle of the cut should match the slope angle of the end being
cut. (Figure 31)
Place one of the modied smoke dome large pieces
(39 3/4” bottom length) on top of and ush with the rst tier
of smoke dome components at the back of the rst course of
smoke dome. The haunched, un-cut end of this piece should be
ush with the haunch end of the rst tier smoke dome below it.
(Figure 32)
Step 17: Repeat this arrangement at the front of the smoke
dome.
Step 18: Cut each of the remaining two smoke dome medium
pieces, part 11, at an angle cut that is parallel to the un-cut end
and so that its bottom length is 23 3/4” (Figure 33).
Step 19: Place one of the angle cut smoke dome top medium
pieces at the front and one at the back of the rst tier smoke
dome so that they meet the smoke dome large (cut to 39 3/4”
bottom length) already set in Step 16. (Figure 34)
Step 20: Set the smoke dome sloping side walls, part 34, in
place between the front and back smoke dome arrangements at
their proper locations at each end of the smoke dome. (Figure
34).
Note: Be sure to put Earthcore Mortar on the contact surfaces of
the vertical joints where the components connect. Look for some
mortar to squeeze out along the joints of all contact surfaces
as a sign that the joint is thoroughly sealed with the approved
mortar. Fill any and all gaps in the assembly, as necessary, with
the approved mortar.
Assembly Instructions - 60” (cont.)
FIGURE 29
FIGURE 30
FIGURE 31
FIGURE 32
FIGURE 33
FIGURE 34

19
Assembly Instructions - 86072 - 60
The overall width dimension at the top of the smoke dome should
be approximately 53-1/2 to 54”. (Figure 35)
Note: The Magnum 86072 - 60 is designed to operate with two
ues. The top of the smoke dome allows for the placement of two
Isokern Modular Masonry DM chimneys or two solid fuel listed
metal chimneys of the appropriate size.
Step 21: Smoke dome top plate small, part # 77A, two required,
must eld cut to t.
Each of the two smoke dome top plate small, part # 77A,
will sit side by side on the smoke dome assembly, meeting at the
centerline of the smoke dome as a butt joint. The top plate, as
standard, comes with a recessed edge (or, a thickened center).
The recessed edge is approximately 3/8”and is intended to be the
bottom face of the top plate.
Each of the two top plate pieces must rst be cut in width
in order to t the overall smoke dome. Each top plate is to have
its width cut by 5”. (Figure 36). The cut edges must then become
the butt joint of the two top plates when set into place. (Figure 37)
Therefore, the width cuts for each top plate must be on opposite
edges of each piece.
The un-altered end of each top plate sits at the end of the
smoke dome assembly and rests on the smoke dome sloping side
wall.
At the recessed edge on the underside of the un-altered
ends of each of the two top plates, the thickened part of the top
plate will need to be ground down ush with the recessed edge
of the top plate so that the underside of the top plate does not ride
high on the smoke dome sloping sidewall.
Place the two top plate components on top of the second
tier smoke dome arrangement so that they meet at the centerline of
the smoke dome. (Figure 37)
The outlet hole sits closer to the back of the smoke dome.
The smoke dome top plates should sit ush with the front and back
of the smoke dome.
The top width dimension of the completed smoke dome
should measure approximately 53 1/2”- 54”. Each top plate has a
width cut dimension of approximately 27”. Two of the top plates
butted together should equal the smoke dome top width dimension
of approximately 54”.
The top plates may have some overhang at the ends of the
top plate assembly, which is acceptable.
Note: Be sure to put Earthcore Mortar on the contact surfaces of
the vertical joints where the components connect. Look for some
mortar to squeeze out along the joints of all contact surfaces as a
sign that the joint is thoroughly sealed with the approved mortar.
Fill any and all gaps in the assembly, as necessary, with the
approved mortar.
FIGURE 35
53½”
5”
FIGURE 36
FIGURE 37

Assembly Instructions - 86072-72
The Magnum 86072 - 72 is a custom unit made of standard parts
that are cut and tted together in the eld. The following cut
and assembly instructions identify the parts by name and by
part number, the quantity required, the eld cut dimensions for
each modied component and the placement of each part in the
assembly.
Note: At all component placement, be sure to mortar all contact
surfaces with Earthcore Mortar. Check for complete sealing of
each contact joint while assembly progresses.
Step 1: Base plate, Part # 91, two required . These pieces are
used “as is”, without any eld cutting required.
Set the two # 91 base plate components on an appropriate
masonry foundation and positioned exactly where the rebox is
to sit. Set the two pieces so that the centerline of the grouping
is a butt joint. This makes for square ends at both the left and
right ends of the grouping. The overall length of the base plate
assembly should measure 85 1/2” and 28” inches deep. Figure
38)
Step 2: Side wall, part # 60, eight pieces required, used “as is”.
The rebox side wall components are used without
modication. The side wall pieces stack four high on both the
left and right hand ends of the base plate arrangement (Figure 39)
The stack of four rebox side wall components will be
assembled in conjunction with the rebox back wall components
described in the following steps.
Step 3: Back wall, part # 67, eight pieces required, four pieces to
be “eld modied”.
Cut the tongue off one end of each of the four # 67 back
wall components. After cutting, each of these four cut pieces
should measure 38 1/2” from the cut end to the shoulder of the
un-altered end (Figure 40).
Step 4: Back wall, part # 67, four pieces required, to be
“eld modied”.
Cut one end of each of the four # 67 back wall
components. These four cut pieces should measure 34-1/2” from
the cut end to the shoulder of the un-altered end (Figure 41).
Step 5: Build the Magnum 86072-72 rebox by setting a 38 1/2”
# 67 Back Wall (from Step 3) on the base plate with its tongue
end interlocked into the rebox side wall positioned at the end of
the base plate (Figure 42).
The square cut end of this 38 1/2” # 67 back wall
component should sit ush with the back of the base plate
with its cut end past the centerline butt joint in the base plate
arrangement. (Figure 42).
Note: Be sure to put Earthcore Mortar on the contact surfaces of
the vertical joints where the components connect. Look for some
mortar to squeeze out along the joints of all contact surfaces
as a sign that the joint is thoroughly sealed with the approved
mortar. Fill any and all gaps in the assembly, as necessary, with
the approved mortar.
20
DISCARD
DISCARD
85 1/2”
38 1/2“
34 1/2”
FIGURE 38
FIGURE 39
FIGURE 40
FIGURE 41
FIGURE 42