Well gang, I just went through my first major clean out of the RMH in my home since the install. I've used it as the sole source of heat for one full season and about half of the season before that. I expected to find some build up, but really wasn't sure how much to expect, or what it would consist of.
Today was the day. I took off the inspection cap for the clean out under the barrel first. There was a build up of incredibly light, almost so light you couldn't feel the stuff, black fluff right there at the cap. As I cleaned that up and reached back into the main flue path, under the barrel, I got into a little heavier fly ash. Light grey, with some dark speckles, this looked like what I expected. It was ash, and had no grit that I could discern. Also, no sticky residue or any indication of any creosote build up. It had built up quite a bit though, mostly on the bottom of the flue pipe. At this location it was probably 2" deep, so was starting to constrict the CSA a bit, although my heater was running great even up to the end of last season.
I used a shop vac, with the output routed through 20' of dust collection hose to outside. I have a 10' hose on the intake of the shop vac, so I was able to snake it around, up into the barrel, and the other way to the first T. It did a great job, blew a little light ash around the house, but not too bad considering. Made a BIG mess outside though, which needed hosing down and probably could use a pressure wash to really move it along.
Anyway, after that I proceeded to the first clean out, which showed me the long run from the end of the bench back to the 90 under the barrel. This one has about 1 1/2" of the fly ash on the bottom of the flue, with a buildup of the lighter black "fluff" all around the flue. Again, it was taking up some CSA, but nothing much. I was able to get the vac hose all the way back around the corner and get the flue totally clean. I had bought a 7" flue brush for this job, and used it because I had it to clean the black fluff off the sides/top of the pipe, but I don't think it was necessary. There wasn't much there.
Then to the last clean out at the end of the other bench. Again, light fly ash on the bottom and fluff all around. Now there was only 1" or so on the bottom, and I was able to get the vac hose back to the back corner to meet what I had done from the other side, and down the other flue to the bottom of the exhaust.
Overall, I'm exceptionally pleased, and relieved. I really didn't know what to expect, and in all honesty I thought it would be much worse, especially considering I hadn't done it last summer. The whole thing took about an hour, I made a bit of a mess, but less than I used to make cleaning the flue/chimney of the old box stove. Actually, as for dust in the house, it was pretty much on par with shoveling out the firebox monthly on the old smoke dragon box stove. I've got some photos I'll put up later. I'm really happy to share this report, this is something I've not seen much real dialog or photos of people getting inside these things after regular use.