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I saw a post of yours when I was Googling a situation with my Lennox (Armstrong) oil hot air furnace. My symptom too is a hot-spot on the outer cabinet in the EXACT SAME SIDE, LOCATION, SIZE and SHAPE. Although my service / installer indicates that this is normal, it is troubling that it is 265F. Being an Engineer, I looked at all the cut-away views in online literature, and I can see the close proximity of the heat exchanger to the cabinet. The exchanger weld in on the opposite side of the furnace, therefore so weld integrity is a moot point. The problem seems have been there from when I built the house. So, my guess is that the heat exchanger is okay, yet still… I will not buy this one again. It is sold under MANY different names (some colors tan, some blue, some green), but is easy to identify and comes with either top exhaust or back exhaust. I was happy though to see the post because it seems to be inherent on this model in general, being in the same exact location.