Heating element wire connection

[wc86]

Does anyone know a good way to redo connections to these nasty heating elements? Im envisioning some sort of small butt splice with screws on both sides. I assume all the spade terminal connectors will be unsalvageable.

 

[LarryFine]

Im envisioning some sort of small butt splice with screws on both sides.

Agreed, or small split bolts.

 

[jim dungar]

Why not new 1/4 tab connectors designed for heating elements? I believe they are stainless steel.

 

[micabay]

You need to replace the heating element too, or else the new terminal will fail shortly.

 

[retirede]

When the connections to the element on my electric smoker failed, there were only wire stubs left on the element - no way to use the connectors it was designed for. I used split bolts and it worked fine for several years. Eventually, the controller failed and I junked the whole unit.

 

[wc86]

You need to replace the heating element too, or else the new terminal will fail shortly.

If I just reconnect the wires why would it fail?

You need to replace the heating element too, or else the new terminal will fail shortly.

Ooo do you have a link?

 

[Hv&Lv]

I would think the 14-8 butt splice Larry posted would be the best option. They are easy enough to get from big blue or big orange. A supply house may have them but they will probably be in a splice kit.
Quickest and easiest, and easier to repair should it ever need it.
You can't really get at it good enough to prepare it for soldering, and it looks like some tried that before without any luck apparently.

 

[LarryFine]

You can't really get at it good enough to prepare it for soldering, and it looks like some tried that before without any luck apparently.

Soldering is never the best method of connecting to a heating element.

 

[Frank DuVal]

Silver solder maybe, not the tin/lead or tin/antimony alloys that melt ~ 600°F! And I mean the silver solder (hard solder) sold for HVAC tubing work, not the electronic 3% silver soft solder that melts even lower than tin/lead alloy!

 

[drcampbell]

I think you're referring to silver-phosporous silver brazing.

https://ch-delivery.lincolnelectric.com/api/public/content/7cdc09a3e3364eca8d9ecb0145977257?v=7aae3e72

There's more to it than just the melting temperature. Metals lose a significant amount of strength long before reaching their melting temperature.
(as a rule of thumb, half the absolute temperature)

Even HVAC silver brazing probably isn't adequate for the temperature of a heating element. (and it's frightfully expensive) I can't recommend anything other than crimping or welding. Or both.

And no copper or copper-alloy lugs.

 

[junkhound]

Does anyone know a good way to redo connections to these nasty heating elements? Im envisioning some sort of small butt splice with screws on both sides. I assume all the spade terminal connectors will be unsalvageable.

way back in 1977 the heating element in my wall oven failed. Right at the plug in spade was failure spot, less than 5 years usage.

My fix: I brazed (actually could call it welded, used Cu wire as brazed rod) a couple of 2 ft long 260C rated 10AWG nickel plated glass fiber filled teflon wire to the spades, then wire nutted to the 8 AWG thhn feeders from the CB panel. Here it is 2024, and SAME element has not failed in all those decades, where the first one failed (same brand Whrilpool) in < 5 years. Threw away the existing oven feed wires and connections.

 

[garbo]

We used to use special T&B sta kons that were made for high temperature. They had a triangular crimp and was made in a different type of material & thicker then standard T&B sta kons. Not sure how good of a mechanical connection they would make on a solid round stud but never had one burnt up when we used it on high temperature stranded wires.