How to Repair an Oil Burner Flue

Inspect the flue. The flue goes from the oil burner to the outside, and may be mounted either on the side or top of the oil burner. Look for the following signs of flue deterioration: flaking plaster, or wallpaper, wall stains and excessive soot; all of these are signs of a leaky flue. Also, check for any loose sheet-metal flue sections.

Determine the section of flue to be repaired. If the flue section is connected to the other sections with sheet-metal screws, use the appropriate screwdriver to remove them all. If connected with rivets, drill each rivet out with a portable drill and drill bit. Remove the section from the flue.

Replace the sheet-metal section with a new one. Measure the section to know exactly what size to purchase. Make the section into a tube by connecting one section to the lip on the other end section. Fit the section into the flue, using a sheet-metal crimping tool around the edges to decrease the tube's diameter, allowing it to fit into the other sections. Gently squeeze the edges with the crimper, taking care not to over crimp.

Drill new holes into the flue, using the holes in the remaining old sections to line up your drill bit. When finished, place a pop rivet into the rivet gun, insert it into the hole and squeeze the rivet gun. Add a new rivet and repeat for each hole. Both the top and bottom of the section must be secured in this manner.

Wrap foil tape around the joining seams of the new and old flue sections. Overlap the tape to ensure a good sealing. This helps seal the flue sections from leaking.