Wiring – How to Repair a Broken Nichrome Wire Heating Element

wiring

I have a broken nichrome wire on my Holmes Accutemp portable heater people say regular solder won't work to reconnect it because the nichrome wire (heating element) may just melt the solder when the heater is in operation.

Does anyone have any other suggestions to connect it back together? I've included an image with an arrow showing the break.

nichrome wire break

Best Answer

I would drill another hole to rivet to the end of that heater wire then make a connection between the new rivet and the old one or the new rivet and where it was connected to.

Did that several times but the devices usually failed as all the other bits are also old...

Edit based on comment: I used to work on 1% ie If the broken bit is less than 1% of the total length then it makes little difference, but if the broken bit was 20% then it causes the remainder to get too hot.