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EL Wire Troubleshooting Answered

Hey everyone,

I use EL Wires to make small neon signs and I've never had any problems with them until I started shipping them places. I have no idea how to fix these things and one of my customers told me the wire is detached from the transformer. Is this fixable?



You could reinforce the point where they report breaks, say with a blob of hot glue, but I can't give much better help without seeing a photo of the damage.

Hi there, thank you for responding, I added a picture, do you think you could help?


So, it snapped off the circuitry inside the box?

A standard reinforcement is to put a knot in the wire, just inside the box, with a bit of slack between the knot and the point where they solder to the board. Any stress from tugs and pulls is taken by the knot on the box, rather than the soldered joints.

If you don't want to tie a knot, or can't, then you need some other way to tranfer forces from wire to box.

If you're selling these, you probably want to hide the fix, so I would sit a bunch of opened transformers in front of you, mix up a batch of two-part epoxy and add a blob to the wire + box inside the box, so that, when it's cured, tugs on the wire do not get transferred inside.

Thank you very much for your help, I appreciate it.