Internal wiring/splice replacement.

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Chris Krahn @relevantworm

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Posted: 4 days agoJul 13, 2026

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Internal wiring/splice replacement.

I have a vintage Sunbeam Radiant Control T-40-1 toaster which has unfortunately suffered from a melted internal wire, probably due to poor insulation leading to a short.

I've purchased a replacement high-temperature wire, but I'm a little stuck on how to actually get the new wire back into contact with the heating element. Sorry if the photo isn't clear, but the end element is the coil at the top of the frame which is fed through an insulator and then immediately into the old wire crimp (or at least I think it's a crimp.)

How do I go about either removing the old crimp or otherwise making room to get the new wire where it needs to be? And then what would I use to secure the splice, would I solder it or use some sort of butt connector? Whatever I use needs to be able to survive the intense heat from being right next to the element.

Am I better off trying to source a replacement coiled nichrome element?

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F Dryer @notbroken Rep: 1.9k 5 4 1 · Answer 1 · 2026-07-13T18:50:13-07:00

Heating elements are electrically welded to and crimped to either a metal pin or spade lug. Wiring with pin receptacle or female spade lug crimped to wiring connects physically to ensure expansion and contraction of heating element temperatures connected to wiring never come apart. DO NOT SOLDER heating elements to wiring! This does not replace welding a pin or wires to nichrome. Soldering is not a substitute for welding. Welding melts metals. Soldering is a form of low temperature lead or lead free metal that glues metals together and will come apart the first time heating occurs. You would create an electrical hazard and endanger yourself and anyone using diy repairs to a toaster. Ceramic and mica spacers are used to physically separate heating elements and wiring from coming in contact with metal parts of the toaster, A third wire is ground for safety against electrocution if a toaster fails and creates a dangerous short circuit condition.

Examine the other end of the heating element still connected to wiring. It's safer and wiser to have this repaired by a small appliance repair shop.

Toaster

Internal wiring/splice replacement.

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