Vermont Castings defiant iai User manual

MODEL #: 0019 & 0028 DEFIANT I & IA
FEATURES: Manufactured 1975 through 6/80, Defiant I has a one piece fireback; Defiant 1A is a
Defiant I converted to a two piece fireback, sides wrap around the front; Defiant IAI is a
I or IA converted to a two piece fireback & two piece baffle, sides wrap around the front.
* denotes dead product - no substitute
ITEM # PART
#
DESCRIPTION ITEM # PART
#
DESCRIPTION
1 130-0072 Bottom No Ash Lip N/A - See Sub 26 000-5838 Set of Two Griddle Tabs (120-1857)
Sub 130-3148 and drill alternate tie rod holes 27 500-5483 Thermostat Assembly
2130-0021* Back 27a 120-1960 Thermostat Ball Chain (per foot)
3 500-0199 Left End with Door 28 120-1846 Tension Spring for Thermostat
4130-3024* Right End 29 160-1555 Thermostat Flap Pin Only
5 130-3162 Primary & Secondary Air Tube 30 000-5800 Thermostat Flap w/ Eyelet
6500-0200* Front with Doors 31 120-0417 1/4-20 x 1/4" Socket Set Screw
7 130-3048 Lower Fireback D1A & D1A1 32 120-3290 3/8-16 Large Pawl Jam Nut
Single Piece Fireback Not Available 33 120-1432 3/8-16 x 1" Hex Head Cap Screw
8 130-0115 Baffle Support D1A1 000-5807 Leg Bolt Set w/ Washers & Hdle Holder
9 130-0110 Baffle D1A1 120-1463 3/8-16 x 1 1/2" Special Long Leg Bolts
10 130-3040 Upper Fireback D1A & D1A1 34 160-0546 Door Pin
11 500-0323 Damper With Welded Pin 35 120-0436 Striker Bolt Only
12 130-0055* Smoke Shelf 36 120-0889 1/4-20 x 1 1/2" Phillips Flat Head
13 160-1487 Thermostat Cove
r
37 160-0575 Finial Nut
14 130-3192* Rear Exit Insert 38 120-1007 10-24 x 3/4" Phillips Trs Head
130-3200* Top Exit Insert 39 500-7497 Set of 4 Tie Rods (160-1617), Washers & Nuts
15 130-0088* Rear Exit Top 39a 120-2461 Star Washer (included in 500-7497)
130-0093* Top Exit Top 39b 120-3226 1/4-20 Hex Head Nut (included in 500-7497)
17 130-3000 Side Load Door 40 120-3210 Striker Bolt Nut Only
18 130-3170 Side Ash Lip (later D1 models only) 41 500-4024 Pawl Assembly (no jam nut)
19 130-3008 Right Door 42 120-0865 1/4-20 x 5/8" Phillips Flat Head
20 130-3016 Left Door 43 500-4244 Side Door Handle Stub w/ Shaft
21 130-3154 Griddle 44 500-4237 Front Door Handle Stub w/ Shaft
22 130-3225 Leg (one only) 45 120-1338 1/4-20 x 1/2" Hex Head Cap Screw
500-0360 Legs (set of 4) 46 120-0563 5/16-18 x 5/16 Socket Set Screw
23 130-0671 Secondary Air Control Cover 47 120-2488 Washer for Leg Bolts
24 500-4265 Damper Handle Stub w/ Set Screw 48 120-6382 Fireback Secondary Air Screen
25 120-1010 10-24 x 1 1/2" Truss Head Phillips 49 120-0998 10-24 x 1/2" Phillips Heat Shield Hole Screw
ITEMS NOT SHOWN ACCESSORIES
000-4342 Fallaway Handle Complete 000-0124 Defiant Screen
160-0620 Ceramic Handle Only 000-0868 Set of 4 Short (3") Legs
120-1294 Handle Screw
160-0650 Handle Stub
120-1832 Handle Stub Roll Pin
REPAIR KITS
000-5832 DEFIANT 1A1 FIREBACK KIT (B
)
000-5825 Box 2 - includes: upper fireback, lower fireback, tie rods, hardware, screen, cement & instructions
000-5830 Box 3 - includes: baffle, baffle support, air tube, hardware & paint
instructions.
500-0199 LEFT END WITH DOOR
This part is needed only on stoves with the original one-piece fireback
GASKETS
120-3588 5/16” Medium Density 6ND Gasket 4.5' Upper Fireback
7' Front Doors
4' Side Doors
120-3668 5/16” Gasket Wire Fiberglass with Core 4’ Top for Griddle
DEFIANT I
,
IA & IAI

DIAGRAM # TO ACCOMMODATE THIS HOLE DRILL SIZE TAP SIZE
A Thermostat hole #22 10-24
B Thermostat cover screw hole #22 10-24
C Air shutter pin holes 1/8" x 3/22" deep N/A
D Damper pin hole #W (.3860") N/A
E Door handle holes 3/8" N/A
F Secondary air cover screw hole #22 10-24
G Air tube screw holes 5/16"
H Ash lip holes 13/64" 1/4-20
I Leg bolt holes 5/16" 3/8-16
J Top tie rod holes 5/16" N/A
K Door pin holes 3/16" N/A
L Andiron holes #3 (.2130") x 5/8" deep 1/4-20
M Griddle tab holes 13/64" 1/4-20
N Heat shield holes #22 10-24
DEFIANT IAI DRILL AND TAP KEY

STEP 3 REMOVE EXTERIOR CASTINGS
CLEANING
Remove Left End. The Smoke Deflector will fall out.
Use wooden bridge to hold the Front and Back castings in place (FIG. 3)
The Fireback can be loosened by inserting a large screwdriver under the lower
left corner and prying upward.
Lift out the Fireback. If it seems
stuck in place, you may insert the
screwdriver into one of the center air
ports and tap the screwdriver to the
left to slide the Fireback out the open
lft d
N
OTE: The following steps are not necessary for Fireback replacement.
All other castings may be left in place.
Remove Right End Plate. The Air Tube may be left in place.
Lift out Baffle.
Remove wooden bridge and rope.
Remove Front Plate
Remove Back Plate
YOU HAVE NOW COMPLETE THE DISASSEMBLY OF YOUR DEFIANT
At this time, cast plates must be thoroughly cleaned of all furnace cement and ash.
Pay particular attention to the channels, using a hammer and chisel or rounded off
screwdriver. Wire brush all channels to remove pieces of cement. If you are
replacing the Fireback and have left the Right End, Front, Back and Right Baffke
in place, it is helpful to use a vacuum cleaner to remove dust and particles from
the castings and stove bottom.

DEFIANT ASSEMBLY
Lay all the parts out on the floor in sequence. We recommend that you assemble the stove once without
cement (dry fit) to make sure all the parts fit. New parts may have to be ground or filed.
At this time, regasket the front and load doors. Replace the door pins if necessary. Be careful when
knocking the door pins out not to fracture the cast hinge bosses.
Check the movement of the door handles. If the handles are stiff, remove and clean the shaft and the handle
hole. The door handle hole may be cleaned with a 3/8” drill bit.
All instructions in italics concern cementing or steps for permanent assembly. Follow non- italicized
instructions for the dry fit assembly.
STEP 4
ASSEMBLE EXTERIOR CASTINGS
On the inside of the Bottom Plate, place pieces
of masking tape over the leg bolt holes to
prevent them from filling with furnace cement
during assembly.
Cement all four channels in the Bottom Plate
(FIG. 4).
Position the Front Plate in the channel on the
bottom plate. The curvature of this plate will
allow it to stand on its own.
Set the back Plate in the back channel of the
Bottom Plate. Hold in place with the wooden
bridge.
If using a new baffle
with support leg, attach
the support leg with a
1⁄4-20 x 1”Hex bolt and
nut.
Set the (assembled) Right Inside Baffle to fit
in place between the Front and Back Plates.
The bridge may need to be adjusted (FIG. 5)
Cement the channels of the Right End Plate
(FIG. 6)
FIG. 4 Cement Channels in Bottom Plate
FIG. 5 Setting Baffle into Place
FIG. 6 Cement Channels on Right End

STEP 4 ASSEMBLE EXTERIOR CASTINGS CONTINUED
Set Right End with air tube attached in place,
sliding the channels in the End over the edges of
the Front and Back Plate (FIG. 7). Move the
wooden brace so the two center slots fit over
the Baffle and Right End. The channels in the
Right End hold the Front and Back Plates in
place.
FIG. 7 Position Right End
STEP 5 FIREBACK AND SECONDARY AIR TUBE INSTALLATION
On the inside of the Back Plate, there are two
ribs which make up half of the Secondary Air
Tube (See FIG. 11 below).
Cement along the top of the upper rib and the
front of the lower rib on the Back Plate (FIG. 8)
Cement the edges of the two ribs on the Lower
Fireback (FIG. 9).
Place the Lower Fireback into the appropriate
bottom channel and lean it back towards the
back plate (FIG. 10). Tap the Lower Fireback
to the right into the appropriate channel in the
Baffle. Make sure that all the cement on the
Lower Fireback comes in contact with cement
on the ribs of the Back Plate. The cement will
seal the upper and lower ribs, forming the
Secondary Air Tube.
FIG. 8 Cement Channels in Back Plate
FIG. 9 Back of the Fireback
FIG. 10 Position Lower Fireback

STEP 5 FIREBACK & SECONDARY AIR TUBE INSTALLATION CONTINUED
Lay 24” screen, supplied with materials, on the
top rib as pictured (FIG. 11). Press the screen
into the cement so the extension of the “T” fits
between the top ribs of the Back Plate and the
Fireback. Add more cement to make a tight
seal. You may use a putty knife to smooth the
cement along the top of the Secondary Air Tube.
Run the end of a broom handle or a 1/2” x 1” x
36” piece of wood into the secondary air
channel to smooth the layer of cement and clear
the channel.
Set the Upper Fireback in place, making sure all
the tabs overlap those on the Lower Fireback
(FIG. 12). You do not need to cement between
the upper and lower fireback.
Tap the lower right corner of the Upper
Fireback to persuade it into the channel on the
Baffle.
If the firebacks are separated, grind down the
interlocking tabs so the Upper Fireback sits
down completely on the top of the Lower
Fireback.
Set the Smokeshelf in place on the Back Plate
and along the Upper Fireback. The cutout
corner of the Smokeshelf should be placed in
the back right corner, where the Right Baffle
meets the Back Plate (FIG. 13). Do not use
cement.
Install the damper so that the Right Damper
Pin is in the hole in the Baffle (FIG. 13).
FIG. 11 View From Left End - Placement of
Screening & cement in Secondary Air Tube
FIG. 12 Upper Fireback Placement
FIG. 13 Smoke Shelf and Damper Placement
STEP 6 INSTALL THE LEFT END
Cement the channels on the Left End Plate as
indicated (FIG. 14).
Smoke Deflector Ridge
FIG. 14 Cement Channels
in Left End

STEP 6 INSTALL THE LEFT END CONTINUED
Install the Left End Plate, allowing the left
damper pin of the Damper to go through the
hole above the Side Loading Door opening.
Make sure the Firebacks are behind the Smoke
Deflector Ridge (see FIG. 15). Also, check
that there are no burrs of cast iron behind that
ridge. In older stoves, the new Firebacks may
be slightly too long. Grind, if necessary, along
the left edge of the Upper and Lower Firebacks.
FIG. 15
Install Left End
Hammer along the top edge of the Left End Plate until it is set in place. Check that the Damper opens and
closes smoothly and easily. You may have to grind the recess in the upper left corner of the Upper
Fireback, which allows for the rotation of the Damper. If you are rebuilding your stove using the original
Left End, you will now have to replace the Smoke Deflector.
STEP 7 INSTALL TOP PLATE
Place cement in the four channels of the Top
Plate (FIG. 16)
Install the Top Plate. Hammer the upper side
and corners of the exterior plates until the Top
Plate sets down over them.
FIG. 16 Cement Channels in Top Plate
FIG. 16 Cement Channels in Top Plate
THIS COMPLETES THE DRY ASSEMBLY.
You may now break down the stove and return to STEP 4 for the permanent assembly with cement.
STEP 8 INSTALL THE TIE RODS
Screw the Finial Nuts on the four Tie Rods.
To install the Left Rear Tie Rod, you may have
to bend it very slightly at a point about a third of
the way up from the bottom of the rod. Guide
the rod down from the Top Plate through the
Bottom Plate. You can see it through the
Ptimary Air Tube hole in the lower hand corner
of the Lower Fireback. Rotate the Tie Rod to
line it up with the hole in the Bottom Plate and it
will slide through.
Install the other three Tie Rods by dropping
them through each hole in the Top Plate and by
reaching inside to line rod up with the hole in the
Bottom Plate. (FIG. 17)
FIG. 17 Install Tie Rods