Picture of Makerbot MK6+ heater replacement
this is a easy heater core  that will get you up and operational from readily available materials for under $1US per core. 
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Step 1: Tools and consumables

Picture of tools and consumables
hookup wire 
30-31gauge coated nicrome wire 
kapton tape 
soldder preferably high temp 
1/4" OD copper tube 
furnace cement 


tooth pick 

Step 2: Prep for build

Picture of prep for build
cut approximatively 1" of copper tube i use the edge of the file. !!!warning!!! if you crush the tube you will have to restart!!! 

cut about 300MM of nicrome wire or 6 ohms worth so long as you are within 1 ohm it doesn't really matter  but the closer the better 

strip 1/4" of insulation off the nicrome ends 

cut 2 lead wires about 12" and strip 3/8" off the ends 

Step 3: Nicrome time

Picture of nicrome time
fold the exposed nichrome in to a U shape than thread the lead around and through the U

wrap silver solder arround the twisted lead as shown below 

melt the solder with a lighter not iron (too slow and fails more than half the time for me)

repeat fr the other side of the nichrome wire

once everything is soldered bend the leads opposite directions parallel to the wires as shown below  

wrap each lead individually with kapton tape 

Step 4: Packing the nichrome

Picture of packing the nichrome
with kapton tape wrap the leads together  as shown 

fold the nichrome loosely into fourths 

than fold it like a letter 3 times and this will be close to an inch long 

Step 5: Insulating

Picture of insulating
squeeze some furnace cement out onto a paper plate of similar surface 

the goal is to work the furnace cement in between all the nichrome wire 
so work it in it doesn't matter what it looks like at this point so long as the wire is still in a bundle similar to what is shown below 
AgeingHippy4 years ago
Hey Dude

Why not simply use a Vitreous Enamel power resistor such as this one


It is commonly used in the Reprap heater block design pioneered by Nophead.

Much cleaner and you don't need the cement, nichrome wire etc.
max mulholland (author)  AgeingHippy3 years ago
I would have but the time did not allow for shipping. I bought one of the first MK6+ upgrade kits and the heater core broke in the first 15 seconds and I needed the printer the next day for a presentation so I made one with what I had.