Neon signs are built using glass tubes filled with inert gas, lit by high-voltage transformers. When a tube breaks, either from impact or stress over time, that section of the sign will stop glowing completely. In most cases, this isn’t something that can be patched. The gas escapes instantly, and the tube becomes nonfunctional.
A broken tube isn’t just a visual problem. It can stress the transformer, affect other working sections of the sign, and even pose safety risks. Fixing the issue properly requires identifying the damage, removing the broken tube, and replacing it with a new one that’s matched in color, shape, and diameter.
The first step in any neon repair is turning off and disconnecting the power. Neon signs operate at thousands of volts, so touching the wiring while powered can be extremely dangerous.
After safely shutting off the sign, the technician will inspect the broken section. In most cases, the tube will need to be fully removed. This requires loosening or unclipping it from its mounts and detaching the wiring connected to each electrode. The damaged tube is discarded, and its shape is traced if a replacement needs to be made.
The replacement process happens in a workshop. New glass is bent using a flame and hand tools to match the shape of the original tube. Electrodes are sealed to the ends, the air is vacuumed out, and inert gas is filled inside under pressure. Once tested, the new tube is transported back to the job site and reinstalled into the sign.
Finally, the electrical connections are made, and the sign is powered back on to test brightness, flicker, and safety. A complete repair may take 1–2 hours on-site depending on the job.
In almost every case, no. Neon repair involves high voltage, delicate materials, and vacuum-sealed gas handling. Professionals have access to specialized equipment like bombarding transformers, vacuum pumps, and gas fillers that the average person doesn’t.
Even if you’re able to remove the broken tube, you won’t be able to replicate the sealed environment required for a working replacement. DIY repairs often lead to electric shock, glass injury, or transformer failure. For business signage, this also poses a liability risk.
The cost to repair a neon sign depends on several factors: how accessible the sign is, how complex the tubing is to recreate, and how far the technician has to travel. Basic repairs like replacing a single straight tube usually fall in the $150–$300 range. Transformer or electrical issues may cost more, often $200–$500. If the sign is over 44 feet high, a larger truck or crane may be required, increasing the cost.
LED conversions are also available if you’re looking for long-term durability and energy savings. These require a custom quote, especially if you want to match the original color and style of the neon.
If your neon sign has a broken tube, the best course of action is to have it evaluated by a licensed neon repair technician. Trying to fix it yourself could create more damage or put your safety at risk. A proper repair not only restores your sign but also protects your transformer and ensures compliance with electrical safety standards.
At NYC Neon Repair, we service signs across New York City, Long Island, New Jersey, and Connecticut. Our technicians can diagnose, repair, or replace neon tubing on-site using bucket trucks or ladders. If your sign is vintage or requires matching, we can recreate the exact tube in our shop.
To get started, send us a photo of your broken sign and its location. We’ll review the damage and provide an accurate estimate before any work begins.
We can’t wait to get started on your project! Big or small, we can do it all. Get connected with our builders for a custom project quote today!
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