Thanks, chem geek!
I used about 30' of 3/4" copper tube to make that exchanger, as a "proof of concept" rig. 3/4" headers, with (6) 3/4" runners set in three layers. I'm actually surprised it's lasted this long.
I'm getting ready to try again on another one, made with 1-1/2" headers and (12) 1/2" runners set at 1" centers. I'll again do multiple folds for a stack 36" long, 24" wide, 10" tall. I'll leave room for baffles between each level, but want to try it first without. I would expect better efficiency with baffles, but that makes it harder to keep ash and combustion debris cleaned out.
I understand now why most of the commercially built wood heaters recommend a smokestack temperature above 450* when firing. At lower temps, creosote builds up on the coils, and doesn't get a chance to cook off, at least that is what I'm finding with my proof of concept rig.
My ultimate goal is actually to build a rig I can use for supplemental house heating. I don't want a pressure system (meaning boiler), just an open system with a couple of circulation pumps to inside exchangers. I'm beginning to see why the commercial systems are so expensive.....