When I first looked into replacing my old boiler with a Weil-McLain CGA-6 Series 3 166,000 BTU Cast Iron Natural Gas Boiler, the sticker price I saw online wasn’t the full story. Like most major HVAC upgrades, there are layers of costs—from equipment and installation to accessories, maintenance, and fuel bills. If you’re planning this investment in 2025, knowing the real numbers upfront can help you budget with confidence.
This guide breaks everything down into clear, digestible sections so you know what to expect.
🏷️ 1. Equipment Cost: The Boiler Itself
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Typical 2025 retail range: $3,800–$4,800 for the Weil-McLain CGA-6.
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What’s included: the cast iron boiler unit, standard manufacturer’s warranty.
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What’s not included: pumps, venting, thermostat, expansion tank.
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How this compares to smaller models (CGA-4, CGA-5).
💡 Samantha’s note: Buying online may save you 10–15%, but always factor in shipping and whether your installer will warranty equipment they didn’t supply.
🔧 2. Installation Costs
Professional installation is often the biggest line item after the boiler itself.
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Labor rates in 2025:
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Northeast & Midwest: $3,500–$5,500
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South & West: $2,800–$4,500
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Includes: old boiler removal, piping connections, gas line hookup, flue adjustments.
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Permits & inspections: typically $200–$600 depending on your city.
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Timeline: 1–3 days, depending on complexity.
👉 Total installation costs typically land between $4,000–$6,000.
🛠️ 3. Accessories & Add-Ons
Most installs require extra parts to make the system run safely and efficiently.
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Circulator pumps: $300–$700 each (multi-zone homes may need 3–5).
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Expansion tank: $100–$250.
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Thermostat/controls: $150–$400 for standard, $250–$500 for smart.
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Zone valves: $150–$300 per zone.
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Chimney liner upgrade: $800–$1,500 (common in older homes).
💡 These “hidden” items can add $1,500–$3,000 to your budget.
🧾 4. Total Installed Cost (2025)
When you add equipment + installation + accessories:
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Low end (basic install, mild upgrades): $9,000
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Average (most homes, typical upgrades): $10,500–$12,500
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High end (complex installs, multiple zones, chimney work): $14,000+
👉 For a large home (3,000–4,000 sq. ft.), budget around $11,000–$13,000 total.
🔥 5. Operating Costs (Fuel & Efficiency)
The CGA-6 has an AFUE of ~82%, meaning 82% of the fuel is converted to heat.
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Annual gas usage: 1,600–2,200 therms depending on climate.
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Average gas price (2025 forecast): $1.20–$1.50 per therm.
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Annual heating cost: $2,000–$3,300.
🔗 EIA natural gas price forecasts
💡 Better insulation and zoning can trim 15–20% off your fuel bills.
💵 6. Rebates, Tax Credits & Incentives
The Inflation Reduction Act (IRA) and many state programs offer rebates in 2025:
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Federal tax credit: up to $600 for gas boilers (must meet efficiency requirements).
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Utility rebates: $200–$1,200 depending on your provider.
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State programs: New York, Massachusetts, Minnesota, and California often offer additional rebates.
👉 Check DSIREUSA for current state-specific incentives.
🧑🔧 7. DIY vs. Professional Installation
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DIY:
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Possible for seasoned DIYers with plumbing + gas experience.
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Risks: voided warranty, code violations, safety hazards.
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Pro installation:
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Adds cost but ensures compliance with gas and safety codes.
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Most warranties require pro installation.
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💡 Samantha’s advice: Boilers aren’t like water heaters—you want a licensed pro for peace of mind.
📊 8. Cost Comparison: Weil-McLain vs. Other Brands
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Burnham: Similar pricing but fewer distribution channels.
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Slant/Fin: Slightly lower cost but less cast iron durability.
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Lennox/Carrier: Often more expensive, branded premium.
👉 Weil-McLain sits in the “mid-premium” category—more than builder-grade, but designed to last decades.
📝 9. Samantha’s Real-World Budget Example
For my 3,400 sq. ft. colonial in Pennsylvania:
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Equipment (CGA-6): $4,300
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Installation: $5,200
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Accessories: $2,000 (3 pumps, new thermostat, expansion tank)
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Chimney liner: $1,000
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Rebates: -$600 federal + -$300 utility = -$900
Total net cost: $11,600
Annual gas bill: ~$2,400.
✅ Key Takeaways
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Expect $9,000–$14,000 total installed cost in 2025 for a CGA-6.
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Operating costs average $2,000–$3,300/year depending on climate.
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Rebates and tax credits can trim $500–$1,500 off your bill.
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Always budget for accessories and hidden upgrades.
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Samantha’s advice: Over-budget by 10–15% to cover surprises.
In the next topic we will know more about: Single vs. Multi-Zone Heating: Can the Weil-McLain CGA-6 Handle It?
