The Smell of Molten Projects in the Morning

Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.

The New Hotness

  • Sunbeam 3035 Clothes Iron: Rusted Spring

    Some weeks ago the Sunbeam clothes iron Mary uses for her quilting projects stopped retracting its cord and a few days ago the entire compartment holding the cord spool simply fell off:

    Sunbeam 3035 Iron - detached cord compartment
    Sunbeam 3035 Iron – detached cord compartment

    One plastic stud and two thin plastic tabs held the compartment onto the rest of the iron. How they lasted this long I do not know, but they are neither replaceable nor fixable.

    When you see badly rusted screws in an electrical device, you know the story cannot end well:

    Sunbeam 3035 Iron - cord connections
    Sunbeam 3035 Iron – cord connections

    And, indeed, it hasn’t:

    Sunbeam 3035 Iron - retraction spring rust
    Sunbeam 3035 Iron – retraction spring rust

    This being a steam iron, it has a water tank that gets filled through an awkward port with a sliding cover. Mary is as conscientious a person as you’ll ever meet, but the occasional spill has certainly happened and it is painfully obvious the iron’s designers anticipated no such events.

    The coil spring had rusted into a solid mass:

    Sunbeam 3035 Iron - spring rust - detail
    Sunbeam 3035 Iron – spring rust – detail

    I removed the spring, soaked it in Evapo-Rust for a few hours, then cleaned and oiled it:

    Sunbeam 3035 Iron - relaxed spring
    Sunbeam 3035 Iron – relaxed spring

    Rewinding and reinstalling the spring showed it has lost its mojo and cannot retract more than a few feet of cord.

    She’s in the middle of a quilting project and will replace the iron with whatever cheapnified piece of crap might be available these days. Similar irons have reviews reporting they begin spitting rust after a few months, which suggests the plastic tank or stainless steel hardware in this one have been cost-reduced with no regard for fitness-for-use.