Tips and Tricks for Changing Elements in an Electric Kiln

Recently, I had to change the elements in my Skutt KM-1027, and I wanted to share some tips to help make the process smoother—especially for those tackling it for the first time. While replacing kiln elements can seem intimidating, a little preparation and the right approach can make it much more manageable.

Safety First

Before doing any work on your kiln, always unplug it or turn off the breaker. This may seem like common sense, but it’s the most crucial step when dealing with any electrical component.

Organization and Preparation

• Label Everything – Once you start cutting wires, it can be difficult to keep track of which one is which. I recommend using tape and a Sharpie to label each wire before making any cuts.
• Mark Cutting Points – Use a Sharpie to mark where you need to cut or strip wires. This ensures accuracy and reduces mistakes.

• Twist Wires Before Crimping – Once the wire is stripped it needs to be put into the crimper sleeve. Twisting the wire makes it easier to push through the crimper sleeve and keeps all the skinny wires in place (if its only one wire you'll need to bend it so it's two wires thick see photo below). If two wires are going into the same sleeve, twist them together first for an easier insertion. I also found that it's helpful to twist while pushing the crimper sleeve on rather than forcing it in all at once.

• Find What is Easiest– I found it easiest when I crimped the wire in the crimper sleeve first and then crimped the sleeve onto the element wire. However, the key is to ensure everything is tightly connected, so find a method that works best for you. 

Reminder - Pull test your crimps! It's a hazard if the crimps are not on tight.

• Use a Plastic Bag to Catch Cuttings - Cutting wire can be a little hectic as the piece can fling across the room. This can be a hazard as you don't want it hitting you, causing an accident. This is what I do!
  Place a plastic bag over the piece and cut so the shard will fling into the bag and not into the air. This is why safety glasses are a must...
  
• Work on One Element at a Time – To avoid confusion, replace one element completely before moving on to the next. This will help ensure you don’t mix up wires or connections. I like to tear one element out and replace it fully before moving onto the next.
• Only Open One Element Bag at a Time – Kiln elements come in different amps and positions (top/bottom and center elements, this also depends on your kiln). To prevent mix-ups, keep the element bags sealed until you’re ready to install each specific one.

Handling the Elements and Firebrick

• Vacuum Before and After Installation – There can be pieces of debris from bisque or firebrick in the grooves, so using a vacuum before installing new elements (and again after everything is in place) helps keep your kiln clean and functioning efficiently. Material on the elements can age them faster.
• Removing Old Elements – Be as gentle as possible to avoid breaking the firebrick. If elements are difficult to remove, try twisting them slightly or even stretching them a bit to help ease them out of the grooves.

Note - It can be hard to take elements out because they expand when they get old. See the first photo showing old vs new elements.

Tools I Used

• Ratchet Crimper & Wire Stripper/Cutter Set (Amazon) – I prefer a ratchet crimper because it requires less force and creates a secure connection.
• Jewelry Long Nose Pliers – This is what I had on hand, but any needle-nose pliers will do. (Here is an example  of a long nose plier on Amazon)
• Strong Wire Cutters – The element wire is very hard so make sure you have good wire cutters. (Here is an example of a wire cutter on Amazon)
• Tape & Sharpie – Essential for labeling and marking cut points.
• Shop-Vac – Any vacuum works, but a shop-vac is especially effective at getting all the dust gunk out.
• Respirator – I wore one to avoid inhaling fine dust particles from the firebrick and other debris. (Here is an example of the filter for the respirator on Amazon)
• Safety glasses – (Here is an example of safety glasses on Amazon)

Changing kiln elements takes patience, but with the right tools and approach, it doesn’t have to be overwhelming. Hopefully, these tips make the process easier and help you feel more confident working on your kiln!