The new heater went in well despite being a pretty big job to do while on the road. Thanks to all who offered advise. Herb's solution to the problems are the simplest and best I've researched. The hinged Chimney is a good idea, and I was able to find foot long stainless piano hinge of the shelf at Lowe's, which trimmed easily. The six gallon suburban gets hot very fast, and seems to last even through a long shower.
Also the burner is much quieter. I wrapped the whole water heater in that silver bubble pack insulation that you can also get from Lowe's. The water stays hot very long and the heater cycles so much less because of it. That stuff was developed by NASA-- or so I'm told-- and if you duct rape together a bag of it, makes for a great beer cooler!!
Alex Kensington, Full Timing with
Charon Henning, The Most Dangerous Beauty Alive™
1966 Safari Overlander & 1961 Safari
1956 Spartan Imperial Mansion
TCT Since 2002, 8728,