I really appreciate your comments and build-notes, both here and on the KS thread, too.
Like you, I find the B&D TO1675B an attractive model for turning into a reflow oven.
A few questions (don't worry most are Yes/No, or short answer!):
How well does your larger oven work?
Does it have <some reasonable amount> of excess up-slope heating capacity? Meaning, does it have any trouble getting up to temp, quickly enough? (My concern is 'barely' being able to run a lead-free profile. Like you, I would insulate the shell).
Do you remember the size/dimensions of PCB support plate you made (so I can get one made-to-order)?
Was one roll of the Reflect-A-Gold tape enough? I get that this is a labor-intensive step!
Ever done several boards at once? Any consistency or 'even-heating' problems?
Do you have any real feel for whether having a convection-type oven makes a difference... is the heating any more uniform?
Thanks again for any insights you can offer.