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Brett, I'm confused. You say they are each in their own box and then you say it's a double gang box. Clarification please.
it's a double-gang shallow plastic box with a double mudring that has just 1 switch slot centered in it.
see attached box.jpg:
or better yet - here's a photo of the two offending dimmers in question. pre and post insulation.
oh - and to canuks comment, both of these 3-way switch circuits are on the same branch circuit. they are the only thing on this light circuit.
Solid state dimmers are notorious for the amount of heat they develop. It's possible that you are trapping to much of the heat and that is what is causing the failures ,although I would think the setup you have should work with the smaller loaded circuit. Suggest you contact the manufacturers tech support or try a different brand of dimmer.
Here's one thought, I wonder if a metal mud ring would help dissipate the heat.
jim - you're a funny man! i drywalled already and my patchup-mudding skills aren't worthy enough :)
But your skills improve with practice.:D
true. today i got up at 5am to bbq a 10lb pork butt, did a huge dump run, baked cookies, poured concrete, installed a toilet, reglazed a door, picked out my 55" LCD TV for the basement project finale, and drank copious amounts of beer. not sure where i'm going to squeeze in all that extra mudding practice ;)
I'm wondering is drilling a couple of holes in the bottom and top rim of the mud ring will help.
is that foam in the box? I wonder if there is not enough free air in the box.