How to cut and make gaskets by yourself for your boiler

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  • OVERALL DIFFICULTY INDEX: 2/10
  • IF YOU HAVE NO TOOLS, YOU PAY $20 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 1 HOUR TO CARRY OUT THIS JOB
  • SAFETY: GASKET PARTICLES SHOULD NOT BE BREATHED, WHATEVER THE GASKET MATERIAL
BEFORE YOU START
See the bottom of this page for the links for boiler maintenance, cleaning and servicing.
DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction.
Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability.

Boiler maintenance intervals 

It is recommended to service boilers equipped with oil-fired burner based on the below intervals:

Yearly boiler maintenance
  • Check for fuel leaks
  • Check for fumes leak
  • Check and adjust burner electrodes
  • Start boiler and check and adjust flame
  • Make sure the hot water circulation pump is not stuck

Maintenance to be carried out on boilers every 2 years
  • Clean boiler from soot and deposits
  • Replace gaskets if and when needed

Maintenance to be carried out on boilers every 3 years
  • Replace burner nozzle and electrodes

When to replace boiler gaskets

It is recommended to replace the boiler gaskets as soon as you notice:
  • Fume leaks leaving a black trace on the boiler front panel
  • Deteriorated and burnt gaskets when dismantling your boiler for cleaning

Cutting and preparing replacement boiler (or stove) gaskets

The use of a good dust protection mask is mandatory
Before purchasing new gaskets, start by removing the existing ones.
They could be held in place by the means of bolts like in this case.
Take them out carefully as you need them to remain in one piece for later using these as a template to cut new ones.
If you're lucky, you'll find replacement gaskets to the right size based on your boiler's model number.
If not, you need to buy gasket paper plates and cut them to the required shape.
Make sure to purchase ceramic fiber material but still the dust mask is a must during this operation.
Put the old gasket on top of the ceramic fiber sheet and mark well openings, then cut them with a cutter.
Punch small holes with a drill.

See all our tips and tutorials for boiler and burner maintenance:

And buy your oil or gas boiler and burner gasket material and parts from our partners' stores:

See also our other tutorials for central heating and home heating: