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Pushing kiln elements back into the groove

Over time kiln elements can sag out of the channel. With each firing the problem gets worse. The elements are far too brittle to simply bend and push back in. As long as they are still in good condition this is the way to do it: Heat them with a plumbers torch and they will be pliable enough to move without breaking.

Pushing kiln elements back into the groove

Related Pictures

Resurrecting and old kiln by replacing elements


Replacing the elements in a old test kiln turns it into a new kiln! Relays are also checked. Notice how the elements are bent and pushed well into the corners. If this is not done properly, they will pull out of the corners after it is fired a few times.

Do these kiln elements need replacing?


Kiln elements need replacing

This 12 inch test kiln has done 910 firings. The element loops are laying down and nearly touching each other. If they are not changed soon the coils will touch the kiln will have hot spots. And the coils are expanding and getting tighter in the grooves, the longer we wait the more the grooves will be damaged when removing them. Although elements seem expensive, when costed on a per/firing basis they can be surprisingly inexpensive. Most hobby kilns service two elements with each relay and relays generally need to be replaced more often than elements. Consider, for example, replacing the elements on a Skutt 818. Being a smaller kiln it is well-powered in relation to size and elements can last up to 1000 firings (assuming 50:50 bisque and cone 6 firings). It has 4 elements and 2 relays (relays cost $65/ea, elements $95 each). The labor to replace is ~4 hours or $250 - total cost is about $750 (that is ~75¢ per firing or 32¢ per ft³). How about a larger kiln? An 8 ft³ Model 1222 has 5 elements and 3 relays and replacement is ~$1100. But its elements are only likely to last 200 firings. That yields a per firing cost of ~$5 and per ft³ of 65¢. But there is a much greater cost to consider: Old elements increase power consumption. An 818 uses 6.4 kwH and a 1222 uses 11.5 kwH - at our electricity cost of 14¢/kwH a firing costs ~$7 for the small kiln and ~$13 for the large one. But that is the cost when elements are new. When they need changing those numbers can more than double! An additional cost of old elements is ware consistency, the kiln cannot execute the firing schedule in the time programmed and this will likely affect the appearance of bodies and glazes.

Links

Articles Electric Hobby Kilns: What You Need to Know
Electric hobby kilns are certainly not up to the quality and capability of small industrial electric kilns, being aware of the limitations and keeping them in good repair is very important.

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