How to Fix a Neon Sign with a Broken Tube
Understanding the Problem
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.
Step-by-Step: How a Neon Tube Is Repaired
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.
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