Wayne - Do you have a favorite supplier of heaters? eBay?
I think I'll try the cartridge type and sandwich it between two steal plates and hold the whole thing in place with the steal sheet that held the mica heater. Not sure I want to drill out the boiler at this point.
I thought getting nichrome wire and mica sheets to make my own, but I'm not 100% sure of the correct wire diameter, number of turns, etc. to make a decent heater.
I found other Empire folks talk about making heaters, maybe someone can post details about their re-builds too.
Jeff