Watch the pilot and flame as it cycles on. If the pilot or flame blows around, gets drawn up off the burner, or tries to blow out, chances are there is a crack or hole burned/rusted through the exchanger.
If that has happened, time to retire it! Not only is it a fire hazard, it will leak carbon monoxide into the room.
If the exchanger checks out, like others have said, be sure there is sufficient heat getting to the thermocoupler. One word of caution, if you take the pilot assembly out for cleaning, don't enlarge the pilot jet while cleaning it! The hole is so tiny, running anything through it will result it the pilot burning too large, wasting gas, overheating the thermocoupler.
I have converted several over to intermittent pilot with this kit. Works well, no more pilot problems.
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Today's Featured Article - A Lifetime of David Brown - by Samuel Kennedy. I was born in 1950 and reared on my family�s 100 acre farm. It was a fairly typical Northern Ireland farm where the main enterprise was dairying but some pigs, poultry and sheep were also kept. Potatoes were grown for sale and oats were grown to be used for cattle and horse feeding. Up to about 1958 the dairy cows were fed hay with some turnips and after that grass silage was the main winter feed. That same year was the last in which flax was grown on the farm. Flax provided the fibre which w
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