How To Do Common Kiln Repairs:


Element Stretching Instructions


Not all elements need to be stretched. Many manufacturers supply pre-stretched and creased elements. Read all manufacturers directions carefully first.


It is important to have even stretch for best element life.


Stretching Elements


1. Mark floor with final stretched length of old element.


2. Partially stretch new element to about 1/3 of final length and examine for even stretch. If stretch is not even, selectively stretch tight lengths with needle-nose pliers.


3. Continue stretch to 2/3 of length and repeat as above.


4. Continue to stretch to full length, repeat as above.


5. Stretch element to a point slightly beyond final stretch so that when tension is released element retracts to final stretch point. Make a mark on floor to reflect beyond point, repeat for all elements.


Note: Before replacing elements, examine element grooves for contamination. If any glaze or clay is in element groove, early element failure may occur. Using a soft bristle brush or a vacuum, carefully remove any foreign matter. Always wear a respirator when using vacuum or use micro vacuum such as Nilfisk.


How To Install Elements


1. If necessary, carefully stretch element according to above instructions.


2. Take the front panel off the kiln which will expose the element connections.


3. Disconnect one element at a time, take it out of the kiln, replace with a new one and reconnect the kiln. If the elements are replaced one at a time, you can't make a mistake.


Note: Make sure your kiln is unplugged before you attempt any repairs.


How To Replace Switches


1. Unplug kiln or turn off power at the source.


2. Remove the switch from the kiln control panel. Leave wiring intact.


3. Transfer one wire at a time to the new switch so that you don't loose track of where the wires go. If you do lose track and are uncertain that you put the wires on correctly be sure to check the wiring diagram.


4. Replace terminals on the wire, especially if there is any evidence of discoloration or oxidation.


5. If the terminals do not fit snugly onto the spades on the switch take some pliers and gently compress the female terminal so that it will be tighter on the spade.


6. Replace switch in control box making sure the top is in the correct position.


Note: Make sure your kiln is unplugged before you attempt any repairs.


Replacing Bricks


Brick replacement runs the risk of breaking a brittle element. Cosmetic damage is sometimes best left alone until you need to replace an element. Replacement of terminal bricks involves cutting and replacing element connectors.


1. Be certain you have the proper replacement bricks before starting.


2. Remove any pins securing the element at each end of the damaged brick.


3. If a sectional kiln, place the ring on a flat surface with the damaged side up.


4. Loosen the hose clamps on jacket until the damaged bricks are accessible.


5. Gently lift the elements from the groove with needle-nose pliers and carefully bow the element enough into the firing chamber to allow removal of the brick. Insert the new brick with the element groove in line with the other bricks. Older elements are fragile and break easily. Have a spare handy.


6. Set the elements into the groove and pin down.


7. Replace the jacket and tighten the jacket clamps taking care to align peepholes. Tighten all screws.


8. Use sandpaper over a wooden block to sand the new brick down until it is even with the adjoining brick.


9. Vacuum the kiln while wearing a respirator, and check the adjustment of the Kilnsitter before firing.


10. Wearing gloves and using an insulated screw drive, carefully retighten the jacket of the kiln again during a firing while the kiln is hot.



Return to the top of this page.
Return to Contents Listing.