I would start it again since there is no ash in the box. thus being no safety issue. so do you have the same unit? the heatmax or the caddy. I can be sure the ash box is the same on both. but in your pic there is welds at the bottom of the box. then it looks to be some square tubing at the top. above that square tubing is where the gap is. looks like some gap in yours too? cant tell from the pic.If it's defective why would you start a fire back in the unit? I just looked under mine, with a fire in the furnace and the blower running and it's fully welded and 100% sealed.
there is no gasket on the ash pan door. you have a different unit. i do understand about draft and chimney pressures and back draft. if you read my post that is where i started. But after 3 hours with the FD and getting a ZERO reading at the register and the only thing we changed was empty the ash draw then why would you think it is anything but the ash draw? dont mean to rain on anyone's parade. still love the furnace. just hope it can be fixed before it kills me.There's no gap, it's a caddy not a tundra. I believe the gap your seeing is where the pan housing goes around the preheat tunnels for the secondary air, that's the only difference I know of between the two. Your ashplug on the firebox isn't sealed 100% between the pan and firebox, that's why there is a gasket on the ashpan door. Was it warmer today where you are? Chimneys can reverse draft, especially with warmer weather. I'm not saying your furnace isn't defective, but a 1400 cfm would turn your ductwork into a dust cloud.
it takes air from upstairs. has its own cold air supply. i can fit my fingers between the gap in the back of the firebox so i know it is not sealed. i would assume that the reason the manual says to keep the ash pan door shut is that it would not circulate air around the fir box causing it to over heat. most of the air would be pushed out thought the ash pan opening and would not circulate enough air around the box.Your ashpan housing is (should) be welded behind the preheat channels on the furnace. If you want to test it, pull the ashpan plug, and keep the ashpan door closed. If the fire ramps up quickly around the ash plug inside the firebox then it's leaking. How is your furnace return ducted, does it take air from the furnace room?
Something sbi should know better on how many thousands will purchase the unit and have no knowledge of this problem . I like mine but it begs the question ;How many people could be getting headaches and fatigue ect ,and not even know about coals in their furnace it seems unusually careless for sbi to not at least not have clear warnings