Use the video walkthrough and the printable guide below to assemble your SaunaBox Forge.

<h3 id="assembly-guide">Assembly guide</h3><p>Use the video walkthrough and the printable guide below to assemble your SaunaBox Forge.</p><p>Video assembly walkthrough:&#xA0;<a href="https://www.youtube.com/watch?v=lkOgAH6sPwk">Watch the assembly video here.</a></p><p><a href="https://cdn.shopify.com/s/files/1/0758/8239/7988/files/Forge_Manual_15-18MB.pdf?v=1785172856">Download the assembly guide (PDF).</a></p><h3 id="need-more-help">Need more help?</h3><p>If you get stuck on a step, email <a href="mailto:support@saunabox.com">support@saunabox.com</a> with your order number and a photo or short video of the step you are on, and our team will help you from there.</p>

Assembly

Your Forge heater should run a full 45 minutes without interrupting. If it cuts out after about 10 minutes, the heater is not broken - the fix is almost always how the stones are packed. Full repack and reset procedure below.

<h3 id="your-heater-shuts-off-after-10-minutes">Your heater shuts off after 10 minutes</h3><p>Forge Sauna &#x2014; early thermal cutoff. Harvia Vega Compact 3.5 kW &#xB7; HCBU352401.</p><p>It should run a full 45 minutes without interrupting. When it cuts out early, the heater isn&apos;t broken &#x2014; two thermal switches on the back wall are getting hot before the room does. Almost every time, the fix is the stones.</p><p><a href="https://cdn.shopify.com/s/files/1/0758/8239/7988/files/Harvia_Vega_Heater_Early_Shutoff_Troubleshooting.pdf?v=1786592929">Download this guide as a printable PDF</a> &#x2014; it has photos of the stone bed that make the back channel easier to spot.</p><h3 id="why-it-trips">Why it trips</h3><p><strong>Hot air takes the empty lane.</strong> The three heating elements sit toward the front of the heater. The two thermal switches sit on the back wall, near the top, behind them. The stones in between are not filler &#x2014; they absorb heat and slow the air down.</p><p>Leave that back channel loose or empty and heat runs straight up the back wall in an unbroken column. The switches read 200 &#xB0;F+ while the room is still cold, and they cut power. Pack the channel full and the heat spreads through the whole bed instead.</p><figure><svg viewBox="0 0 760 400" width="760" height="400" role="img" aria-label="Top-down view of the heater. The three heating elements sit at the front. The two thermal switches sit on the back wall behind them. The channel between them is the area to pack with stones first." style="max-width:100%;height:auto;"><title>Looking down into the heater</title><desc>Elements forward, thermal switches at the back. The stones in the channel between them are what stand between the two.</desc><rect x="0" y="0" width="760" height="400" fill="#ffffff" rx="8"/><line x1="185" y1="30" x2="520" y2="30" stroke="#999" stroke-width="2"/><line x1="190" y1="30" x2="200" y2="14" stroke="#999" stroke-width="2"/><line x1="212" y1="30" x2="222" y2="14" stroke="#999" stroke-width="2"/><line x1="234" y1="30" x2="244" y2="14" stroke="#999" stroke-width="2"/><line x1="256" y1="30" x2="266" y2="14" stroke="#999" stroke-width="2"/><line x1="278" y1="30" x2="288" y2="14" stroke="#999" stroke-width="2"/><line x1="300" y1="30" x2="310" y2="14" stroke="#999" stroke-width="2"/><line x1="322" y1="30" x2="332" y2="14" stroke="#999" stroke-width="2"/><line x1="344" y1="30" x2="354" y2="14" stroke="#999" stroke-width="2"/><line x1="366" y1="30" x2="376" y2="14" stroke="#999" stroke-width="2"/><line x1="388" y1="30" x2="398" y2="14" stroke="#999" stroke-width="2"/><line x1="410" y1="30" x2="420" y2="14" stroke="#999" stroke-width="2"/><line x1="432" y1="30" x2="442" y2="14" stroke="#999" stroke-width="2"/><line x1="454" y1="30" x2="464" y2="14" stroke="#999" stroke-width="2"/><line x1="476" y1="30" x2="486" y2="14" stroke="#999" stroke-width="2"/><line x1="498" y1="30" x2="508" y2="14" stroke="#999" stroke-width="2"/><rect x="200" y="55" width="300" height="305" rx="22" fill="none" stroke="#222222" stroke-width="3"/><rect x="215" y="75" width="270" height="70" fill="#fdf6e3" stroke="#c9a227" stroke-width="2" stroke-dasharray="6 4"/><line x1="220" y1="143" x2="238" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="240" y1="143" x2="258" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="260" y1="143" x2="278" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="280" y1="143" x2="298" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="300" y1="143" x2="318" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="320" y1="143" x2="338" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="340" y1="143" x2="358" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="360" y1="143" x2="378" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="380" y1="143" x2="398" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="400" y1="143" x2="418" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="420" y1="143" x2="438" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="440" y1="143" x2="458" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><line x1="460" y1="143" x2="478" y2="77" stroke="#c9a227" stroke-width="2" opacity="0.55"/><rect x="285" y="66" width="60" height="20" rx="3" fill="#f0a83c" stroke="#b8802a" stroke-width="1.5"/><rect x="380" y="66" width="60" height="20" rx="3" fill="#f0a83c" stroke="#b8802a" stroke-width="1.5"/><path d="M248 168 L248 283 A 17 17 0 0 0 282 283 L282 168" fill="none" stroke="#d94f3d" stroke-width="6" stroke-linecap="round"/><path d="M323 168 L323 283 A 17 17 0 0 0 357 283 L357 168" fill="none" stroke="#d94f3d" stroke-width="6" stroke-linecap="round"/><path d="M398 168 L398 283 A 17 17 0 0 0 432 283 L432 168" fill="none" stroke="#d94f3d" stroke-width="6" stroke-linecap="round"/><text x="14" y="80" font-family="Helvetica, Arial, sans-serif" font-size="15" font-weight="bold" fill="#8a6d1f">PACK THIS AREA</text><text x="14" y="100" font-family="Helvetica, Arial, sans-serif" font-size="15" font-weight="bold" fill="#8a6d1f">WITH STONES FIRST</text><line x1="30" y1="122" x2="184" y2="122" stroke="#8a6d1f" stroke-width="4"/><polygon points="184,113 203,122 184,131" fill="#8a6d1f"/><line x1="445" y1="72" x2="552" y2="72" stroke="#777" stroke-width="1.5"/><text x="560" y="77" font-family="Helvetica, Arial, sans-serif" font-size="14" fill="#444">Thermal switches (2)</text><line x1="434" y1="225" x2="552" y2="225" stroke="#777" stroke-width="1.5"/><text x="560" y="230" font-family="Helvetica, Arial, sans-serif" font-size="14" fill="#444">Heating elements (3)</text><line x1="492" y1="356" x2="552" y2="344" stroke="#777" stroke-width="1.5"/><text x="560" y="349" font-family="Helvetica, Arial, sans-serif" font-size="14" fill="#444">Front of heater</text></svg><figcaption><em>Looking down into the heater. Elements forward, switches at the back &#x2014; the stones in between are what stand between the two.</em></figcaption></figure><h3 id="do-this-first-repack-the-stones-filling-the-back-channel-first">Do this first: repack the stones, filling the back channel first</h3><p>Set aside 20 minutes. You&apos;ll take every stone out and put it back in a specific order. Do not skip the emptying step &#x2014; you cannot tell whether the back channel is full by looking down through the top.</p><ol><li><strong>Cut power and let it cool.</strong> Switch the heater off at the breaker, not just at the knob. If it has been running, give it 60 minutes. Stones hold heat long after the shell feels safe.</li><li><strong>Take every stone out.</strong> All of them, down to the bare element base. Lift them out &#x2014; do not tip the heater.</li><li><strong>Fill the back channel before anything else. This is the step that fixes it.</strong> Reach behind the elements and fill the gap between the back of the elements and the rear wall &#x2014; the full width of the heater, from the element base all the way up to the top edge. Use the thinnest stones you have to fill this area. Work the stones down with your fingers until the channel is solid and you cannot see a clear vertical path up the back wall. This is the single most common cause of an early cutoff. <strong>WARNING: do not force stones in this area, it may damage heating elements.</strong></li><li><strong>Fill between the heating elements.</strong> Next, use the remaining thin stones to fill the area between the heating elements. Make sure the gaps between heating elements are sufficiently stacked with stones.</li><li><strong>Fill the rest, loosely but completely.</strong> Stones should lean on each other and on the heater walls &#x2014; not rest their weight on the elements. Never wedge a stone between two elements. The elements have to stay vertically straight when you are done. Place stones in; do not drop them.</li><li><strong>Fill to the top edge &#x2014; no mound.</strong> Bring the bed level with the top rim of the stone space. Do not pile a heap above the heater; that blocks the airflow the heater needs to move heat into the room.</li><li><strong>Check for bare elements.</strong> Walk around the heater and look into it from every angle, including down through the top. You should not be able to see a bare element anywhere &#x2014; that is both a fire risk and a sign the bed is too thin.</li></ol><figure><svg viewBox="0 0 460 350" width="460" height="350" role="img" aria-label="Airflow through the heater, seen from the front. Cool air is drawn in at the base, rises through the stone bed packed level with the top rim, and leaves as hot air over the top. Piling stones above the rim blocks this path." style="max-width:100%;height:auto;"><title>Airflow through the stone bed</title><desc>Cool air enters at the base, rises through the packed stones, and leaves over the top rim. A mound above the rim blocks the path.</desc><rect x="0" y="0" width="460" height="350" fill="#ffffff" rx="8"/><line x1="95" y1="62" x2="88" y2="22" stroke="#666" stroke-width="3"/><polygon points="82,26 88,10 94,28" fill="#666"/><line x1="150" y1="62" x2="150" y2="20" stroke="#666" stroke-width="3"/><polygon points="143,24 150,8 157,24" fill="#666"/><line x1="205" y1="62" x2="212" y2="22" stroke="#666" stroke-width="3"/><polygon points="206,28 212,10 218,26" fill="#666"/><text x="238" y="30" font-family="Helvetica, Arial, sans-serif" font-size="13" font-weight="bold" fill="#555">Hot air out</text><rect x="65" y="70" width="170" height="215" rx="16" fill="none" stroke="#222222" stroke-width="3"/><line x1="65" y1="88" x2="235" y2="88" stroke="#c9a227" stroke-width="2" stroke-dasharray="6 4"/><ellipse cx="96" cy="108" rx="21" ry="14" fill="#e8e2d6" stroke="#9a8f7c" stroke-width="1.5"/><ellipse cx="143" cy="102" rx="23" ry="15" fill="#ded7c8" stroke="#9a8f7c" stroke-width="1.5"/><ellipse cx="192" cy="109" rx="21" ry="14" fill="#e8e2d6" stroke="#9a8f7c" stroke-width="1.5"/><ellipse cx="90" cy="140" rx="20" ry="14" fill="#ded7c8" stroke="#9a8f7c" stroke-width="1.5"/><ellipse cx="137" cy="136" rx="22" ry="15" fill="#e8e2d6" stroke="#9a8f7c" stroke-width="1.5"/><ellipse cx="188" cy="142" rx="21" ry="14" fill="#ded7c8" stroke="#9a8f7c" stroke-width="1.5"/><ellipse cx="106" cy="170" rx="22" ry="14" fill="#e8e2d6" stroke="#9a8f7c" stroke-width="1.5"/><ellipse cx="158" cy="172" rx="23" ry="15" fill="#ded7c8" stroke="#9a8f7c" stroke-width="1.5"/><ellipse cx="203" cy="168" rx="18" ry="13" fill="#e8e2d6" stroke="#9a8f7c" stroke-width="1.5"/><path d="M100 200 L100 252 A 14 14 0 0 0 128 252 L128 200" fill="none" stroke="#d94f3d" stroke-width="5" stroke-linecap="round"/><path d="M158 200 L158 252 A 14 14 0 0 0 186 252 L186 200" fill="none" stroke="#d94f3d" stroke-width="5" stroke-linecap="round"/><line x1="235" y1="88" x2="268" y2="88" stroke="#777" stroke-width="1.5"/><text x="276" y="84" font-family="Helvetica, Arial, sans-serif" font-size="12" fill="#444">Stones level with the</text><text x="276" y="100" font-family="Helvetica, Arial, sans-serif" font-size="12" fill="#444">top rim &#x2014; no mound</text><line x1="235" y1="226" x2="268" y2="226" stroke="#777" stroke-width="1.5"/><text x="276" y="231" font-family="Helvetica, Arial, sans-serif" font-size="12" fill="#444">Heating elements</text><line x1="95" y1="340" x2="102" y2="298" stroke="#666" stroke-width="3"/><polygon points="96,302 102,288 108,300" fill="#666"/><line x1="150" y1="340" x2="150" y2="296" stroke="#666" stroke-width="3"/><polygon points="143,300 150,286 157,300" fill="#666"/><line x1="205" y1="340" x2="198" y2="298" stroke="#666" stroke-width="3"/><polygon points="192,300 198,288 204,302" fill="#666"/><text x="238" y="325" font-family="Helvetica, Arial, sans-serif" font-size="13" font-weight="bold" fill="#555">Cool air in</text></svg><figcaption><em>Air is drawn in at the base and leaves over the top rim. A heap of stones above the rim blocks that path and traps heat inside the heater.</em></figcaption></figure><h3 id="never">Never</h3><ul><li>Wedge stones between the elements, or let stone weight rest on them.</li><li>Drop stones in from height.</li><li>Use soapstone, ceramic stones, light porous rock, or river rock.</li><li>Put anything else in the stone space, or place objects near the heater that redirect airflow.</li><li>Pile stones above the top edge of the heater.</li></ul><h3 id="confirm-reset-the-overheat-protector-and-run-a-full-cycle">Confirm: reset the overheat protector and run a full cycle</h3><p>The thermal cutoff stays latched after it trips. Until you reset it, the heater keeps behaving as though the problem is still there.</p><ol><li><strong>Reset the overheat protector.</strong> Follow section 3.7 of your Harvia manual &#x2014; <a href="https://cdn.shopify.com/s/files/1/0758/8239/7988/files/Harvia_Manual.pdf?v=1785352536">download the Harvia manual here</a> (section 3.7, &#x201C;Resetting the Overheat Protector&#x201D;, page 11). The heater must be fully cool for the reset to hold &#x2014; if it is still warm, the protector will latch again immediately.</li><li><strong>Restore power and start a normal session.</strong> Breaker on, thermostat at your usual setting, timer set. Note the clock time you started.</li><li><strong>Let it run 45 minutes.</strong> A healthy heater runs for around 45 minutes without the elements cutting out. You will hear it cycle on the thermostat once the room comes up to temperature &#x2014; that is normal, and different from a cutoff.</li><li><strong>Note what happened.</strong> Ran the full 45 minutes? You are fixed. Cut out early again? Write down how many minutes in, then send us the six items below.</li></ol><h3 id="still-cutting-out">Still cutting out?</h3><p>Send us six things and we&apos;ll take it from there. With these in hand we can usually tell you what is happening without a second round of questions.</p><ol><li>A photo looking straight down into the stone bed, taken before you put the last layer on &#x2014; we are looking at the back channel.</li><li>A photo of the heater in place, far enough back to show the wall, the bench, and the floor underneath it.</li><li>The number of minutes from switch-on to cutoff, and whether the room felt warm at all when it happened.</li><li>The serial number from the label on the side of the heater.</li><li>A photo of your main breaker with the labels visible, and the breaker&apos;s type and size.</li><li>A photo of the heater wiring, framed to show a full view of every connection present.</li></ol><h3 id="downloads">Downloads</h3><p><a href="https://cdn.shopify.com/s/files/1/0758/8239/7988/files/Harvia_Vega_Heater_Early_Shutoff_Troubleshooting.pdf?v=1786592929">Early thermal cutoff service guide (PDF).</a> This page as a printable 3-page guide, with photos of the stone bed.</p><p><a href="https://cdn.shopify.com/s/files/1/0758/8239/7988/files/Harvia_Manual.pdf?v=1785352536">Harvia heater owner&apos;s / operator&apos;s manual (PDF).</a> Covers installation, wiring, operation, troubleshooting, maintenance, and the guarantee for the HCBU352401.</p><p><a href="https://cdn.shopify.com/s/files/1/0758/8239/7988/files/Vega_Sauna_Wiring_Guide.pdf?v=1786580520">Sauna electrical installation guide (PDF).</a> For your electrician, if the cutoff turns out to be a wiring or breaker issue.</p><h3 id="need-more-help">Need more help?</h3><p>Email <a href="mailto:support@saunabox.com">support@saunabox.com</a> with your order number and the six items above, and our team will help you from there.</p>

Heater Shuts Off Early - Service Guide

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