How To Remove Cold Cathodes from Tube. Pics & FAQs

Last night I took apart 4 Cold Cathode Tubes, from Oznium.com

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1) Put Tube in vice with the end with the white pointing towards you. Do not over tighten the tube will crack.


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2) Use heat source to melt glue on the inside of end cap. While heating hold the cap with pliers constantly pulling the end cap off.

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3) Once the end cap slides off, slide it down, careful not to burn yourself if you overheated the cap. If you over heat extremely the cap will begin to melt and will stick to the tube. Heat slowly and evenly to avoid this.


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4) Heat the end of the tube where the small amount of glue that holds the element is, once this glue is melted pull the element out slowly and carefully. Be sure not to over melt the glue, it will melt and stick all over the element as you pull it out.

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5) Slowly pull the end cap down the length of the element to remove it. Make sure you remove all excess glue.
You now have an element that is untubed, be careful with it they are very fragile. I am still trying to fiqure out what Phil does with the bare wire to prevent shock?



END OF TUBE DISASSEMBLY.



1) Remove heat shrink from all of Side A. This seperates the two white wires and allows the bare wire to be pulled away from the cathode element.

2) Use screwdriver head, or razor blade to push down the little silver tabs on the quick connect that goes to transformers, thus seperating the two white wires.

3) Remove all of the heat shrink from Side B of the cathode, this frees the wire from that end of the cathode.

4) Now reconnect the quick connect by adjusting the tabs on the end of the wire, and tweaking them once inside the clip.

You now have a cathode that should look like this.


Heatshrink the wires to firm more solid and stable connections on side A & B then you can wrap the bare wire in black tape. For extra protection.

To mount the cathode to headliner, do not connect one of the white wires to the quick connect. Make two holes, fish the white wire, with the bare wire through the hole, make a 2nd hole, and put the other white wire, through, and then simple connect the wires to the quick connect. Your done, a sleek tubeless install...Use fishing wire or needle and thread to secure the cathode element to your headliner.

Diagram of Cathode Secured to Headliner with 2-hole hanging.



Finished product, heat shrunk ends, bare wire wrapped in electrical tape for insulation. (Empty tubes in background.)



Mounted finished product. I removed a piece of trim and put the transformer and the wires behind the trim and tightened the trim up. Use the wires off the element to hold the element in place they are tucked very neatly. I would rather use thread.



FAQs

Q:How do I modify the element so I do not get a buzzing or shock sensation when I touch the bare wire to the element?

Answer from Phil wrote:

To deal with the bare wire you must bring it around to its own side. You can do this by using a cutting blade to carefully remove the white heat shrink. You might have to remove 2 layers of it. You can then use a tiny eyeglass screwdriver to push the pins in the quick connect power plug out so you can remove each white wire. Then, thread them through the holes in your headliners or wherever. Pull the "clips" back out with a small eyeglass screwdriver and carefully insert them back into the power plug. Ohh you probably want to heat shrink both ends of the cathodes for a clean install and to prevent excessive flexing of the wire joints.

Q: How thick is the element once it is removed from the tube?

Answer from Moss wrote:

About 1/8 of an inch thick. Once its untubed its very thin and easy to hide.

Q: Do they break easily once out of the tube?

Answer from Moss wrote:

Yes they have nothing to protect them. They will crack or shatter if hit hard enough. I do no suggest putting them where people might kick or hit them. On your headliner should be safe. As long as they are secure they can handle road vibration.

Q: What’s the black stuff on the end of the element?

Answer from Moss wrote:

It is heat shrink, I suggest using white to match the wires for a cleaner install.

Q: How can I secure to my headliner?

Answer from Moss wrote:

White thread or a color that matches your headliner would be fine just make sure to tie the knots snug. Simply loop the thread around the cathode and through the headliner.

Q: How great is the risk of shock?

Answer from Mav wrote:

risk of shock is next to nothing. It's more of a fire issue. The fuse in the transformers is very weak, and the amperage draw on those is very minute. If you short it however, the transformer can blow and catch fire. That’d be bad =P as for tingle, you can probably touch your tongue to it, and it will feel like a 9v battery. It's amperage that kills you, not voltage. Those things are running at like 1500 volts and like 0.05 amps. Not much at all.

Do I have to follow all the steps and remove the bare wire from the element?

Answer from Moss wrote:

No.

Q: Is there any other way to get the elements out of the tube?

Answer from Moss wrote:

Some members have had their elements come loose or fall out from the heat. I never experienced this, that what I created this tutorial.

This post has been edited and locked to keep it easy to read and more of a How-To. All questions you have regarding this feel free to send me a Personal Message (Just Hit PM below) or send me an instant message on AIM, my screen name is Bromoss790. I will add your questions to this post to share with all. I believe all issues have been covered. I will be glad to help any glower.