Thanks for the offer Dom! But as I said- I cannot accept any offers of financial help.
Well this morning at 3:30am I woke up to the sound of the furnace going snakey (I fell asleep on the couch in the basement last night)! It sounded like a cyclone was happening inside the fan basin!
I took the cover off to find that water was spuing out everywhere! This was one of my worst fears- that the water would get into the fan system and short out the electrical motor (possibly starting an electrical fire).
Water had collected in the fan basin, however it had not gotten into anything having to do with the motor/electrics. I was still scared to death that the water would wreck the furnace somehow, so I devised a plan to siphon the water out. I connected a bunch of straws together hoping to suck the water out (this is half asleep at 4am).
Well... it never really worked. I couldn't suck the water out (although I did manage to get some oily tasting water in my mouth

) as the straws kept bending to the point that they would break/come apart/have air gaps etc.
I even tried wrapping the straws in masking tape to seal the connections- again the straws would bend and not be able to do their job.
Basically I came to the conclusion that I would not be able to run the furnace until it was fixed (I was also half convinced it was ruined at this point- with a new furnace costing $3200.00).
Fortunately, leaving it off all this time allowed the water to drain slightly. I turned the fan on without the hot water tap open (which supplies hot water to the heating coil). Eventually all the water within the basin was blown out by the fan. The whole thing seems fine now.
This all happened because I had not adhered to my rule of only running the furnace for a couple of hours before stopping it and bailing out the water.
Needless to say it scared the kaa-kaa out of me. It's 5am now, and I'm still wide awake.
Kevin
[img]http://groups.msn.com/_Secure/0TgDnAloXyJBkYBZV7s*Kj9!1Bc8b0FJ!WEmX8BpHJk8yRyABH697OsLy1Bm1knQrHcDDdHqDnRAmyoDB6vy6w!ASmCM57J8W6cyCxY8Y84TWwwCw7UVNAA/Burton%20004.JPG[/img]"I know I'm human. And if you were all these things, then you'd just attack me right now, so some of you are still human. This thing doesn't want to show itself, it wants to hide inside an imitation. If it takes us over, then it has no more enemies, nobody left to kill it. And then it's won."