On Wed, 20 Jun 2007 18:10:13 -0000, Ben wrote:

Any suggestions appreciated!

Maybe not what you and the others want to hear, but years ago, when my
kids were in their teens, it became impossible to meet all of the
shower, bath, laundry demands. I simply installed an electric hot
water heater in series with tankless coil output. The boiler then
preheated the water and the HWH kept it hot. Thru a set of
judiciously placed valves I can cut the HWH system out of the system
(In hurricane aftermath, the generator will handle the boiler, but not
the HWH)
My Burnham is 40+ years old; no way would I ever attempt to replace
that coil - nor would my HVAC guy.
Works for me