Ralph,
You might also try this trick with Borax...
(From: Dan Sternberg (
[email protected]).)
Another old trick for nichrome repair is to make a paste of Borax, twist the two broken end together, and energize the circuit. A form of bond welding takes place. I've have used this on electric clothes dryer heater elements with good luck.
(From: DaveC.)
Here's a "quick fix" that sometimes works for a long time and sometimes fails quickly (depending, I think, on just how old and brittle the nichrome wire is).
Mix some ordinary "Boraxo" powdered hand soap with a little water to make a thick paste -- and you don't need much.
Take the broken ends of wire, bend a small loop into each, and interlock the loops so the wires stay together.
Pack the Boraxo paste around the joint, and turn on the heater.
Keep your eyes on that joint. As the coil heats up, the hook joint will be the worst connection, so it'll naturally get the hottest.
When it gets hot enough, the nichrome wires will melt, and, being fluxed by the borate, will fuse together into a blob. The blob, now being *larger* than the rest of the wires, will immediately cool down, and will never again get as "red hot" as the rest of the heater.
Allow the coils to cool down and, using pliers, carefully crush any glassy flux deposit that remains on the joint.
If the joint doesn't behave as I describe, or if the wires are too brittle to be formed into hooks, the wires are likely too old to produce a long-lasting joint. If the joint behaves as I described, it may last for a good long time.