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Well, It's been over a year since I started the process of reproducing the Popperette Popcorn Machine Heating Element and I am finally done and have a properly working product!

The part of the project that took the longest was determining what the original ceramic element was made out of and finding a suitable replacement or matching it exactly. Getting the proper resistance wire to create the element out of took a little bit of work but that was pretty easy considering everything else.

Next I had to find a company that was willing to work with me on a small scale that wasn't going to cost an arm and a leg. I found a great company that did a tremendous job.

Here are a few pics of the final product after I wrapped it.

Looks awesome Brian!
What did you utilize for the replacing the ceramic element? Delrin or some other type of hardened plastic...?

If you have some for sell - I would be interested. Looks like it turned very nice. How long was it tested for?  Please email me.  Thanks - Joe

You can be the grand poo bah in our Popperette club.

Excellent recreation and the modification of the screw head is perfect.

Jim,

I was actually able to determine what the material composition of the original heating element was and went from there. When I first started this project I was new to the world of ceramics but I now have a better working knowledge. Working at a Failure Analysis Laboratory helps too!

So to answer your question, Jim, it's made out of ceramic, not a plastic or glass.

At first I spent a lot of time trying to find a "better" product. That didn't work so well. Most products I found were WAY to expensive in their raw form and that was before machining and firing.

Larry - Yeah, it worked out well, grand poobah? Naw...unless I get a really cool hat to wear!!  :laugh:

Brian,

Great work on something that will keep these vintage machines popping for years to come.

Here's your hat!

 :drinking: Tim :drinking:

Very cool, find a needand fill it. I wish you luck!

Here's a picture of an original heater.  You can see that Brian did find away to make a better mouse trap.  He squared off the interior edges, where the screw heads meet the ceramic.  Hardly any chance of breaking due to overtightening.  Great design. :happydrinkers:

Is the part machined like your grey heater or is it formed and fired.

It looks great!  Are you going to sell any?  I think mine is broken but it's missing a couple of other parts so I haven't really played with it yet.

I would also be interested in at least one, if they are for sale.

Joe -

I am in the process of conducting "lifecycle" testing on the element and will be complete sometime this weekend. I have no doubt that it will be a consistant performer. But, I would not even attempt to reproduce an item without testing it first. That wouldn't be fair to anyone. I would hate for my own design to take a big fat dump on me in my own machine!  :biggrin:

All of the physical properties of the new element body are superior to the original as well as the small modification to provide for a more stable fastening surface for the element resistance wire bolts.

I will give an update when complete.

Brian,  I appreciate the update.  After you have completed your testing and everything has performed as it should, I would be interested in a few of them.  Thanks - Joe       Be-bop Joes 

Joe,

Sounds good.

I will keep all interested parties updated. I will be done testing this weekend.

All,

Just finished up testing of the heating element and it performed like a champ!

I tested it a variety of different ways. I did what I call endurance testing which was to pop multiple batches in rapid succession to see if the element body would be party to heat sturation induced fractures, it isn't, and also to check the shape retention of the resistance wire. I also let time pass between batches to test the resistance wire's ability to fall back into the grooves after expansion, it passed that with flying colors as well.

My 23 month son was my lab assistant and was responsible for witnessing all testing!

If you are interested in an element please PM me. There is a lead time on these but definitely worth waiting for!

Great Brian,
thanks for all your work on these.. I know many will appreciate having a backup, in the event one fails..

I bet your son got his fill of popcorn today too! :biggrin:

That is a great picture. Thanks for keeping parts supplied!!
Creighton

I'm glad the test were succesful! It's nice to have them lab assistance around!!

Now maybe you will have time to paint that stand. :biggrin:

He really enjoys watching the corn pop. My favorite part is when the cam drops into the cut-out and "explodes" the corn out of the cooking chamber, my boy jump every time!! :laugh:

Paint it? Nah....I like the *patina*

Seriously, I hope to get to that this Spring.

Very nice job of engineering on the heating element, Brian.  I also love the photo of your son watching.  If I could bubble-caption his head, it would say, "Yeah, I will be the COOLEST kid in pre-K with this!"