I've never had it happen.

With that washer in there, you might have too much gap. Like Kap said, you only want the door 'sagging' down opposite the pivot by the width of a dime. With gap all the way around, you might be seeing a lazy flame, which is not good.
I take a wood chisel and push straight down and twist it to break up the build up. Keep doing that until it opens smoothly. Someone else recommended cutting a metal piece the shape of the bottom of the pot and placing it on to the clean plate, then all the build up is on the loose metal piece, which falls into the ash pan when you pull the gate. I think that's a great idea but I still haven't gotten around to making it. I have the template but that's as far as I got.

Hello Leve, could you please explain to me where this washer is installed, I have a mount vernon and sticks on me sometimes? thank you in advance..mike.

scatpac1, they are talking about other quad stoves, not the AE that you have. Kap