Picture of the broken plastic lid handle portion of the lid for the Hamilton Beach 40891 Cordless Kettle.

Electric Kettle Repair: Hamilton Beach 40891 Teapot Lid




We love our Hamilton Beach 40891 cordless kettle.  But by necessity, we learned a bit about electric kettle repair, when the lid for that kettle came apart after several years of use.



So, we determined how to repair this break, with pretty good results.

Electric Kettle Repair: How the Kettle Lid Should Look

As pictured next, the lid consists of a stainless steel base and a plastic handle on top.  They secured this heat insulating handle to the metal base with one Philips head screw.  The properly assembled lid appears in the next picture.  Using JB Weld Steel epoxy glue, we successfully repaired the electric kettle lid as follows.

Picture of a lid for the 40891 Hamilton Beach repaired electric kettle, as it should look, unbroken.
How to repair electric kettle Lid, for 40891 Hamilton Beach water kettle, as it should look, unbroken.

Electric Kettle Repair: The Broken Lid

We took the next picture after the handle piece broke.  Note the broken plastic screw standoff fragment, still attached to the metal base.

Picture of the broken plastic lid handle portion of the lid for the Hamilton Beach 40891 Cordless Kettle.
Repair Electric kettle: Broken plastic lid handle on the Hamilton Beach 40891 teapot kettle.

Repair Electric Kettle: Use the Right Glue

We glued the black plastic handle back to the stainless steel lid proper, using a high temperature handling epoxy compound from J-B Weld, pictured next.  We chose this one because, though it takes longer to set than some faster glues, it was the strongest glue that would maintain its holding strength in the high temperature environment of the electric kettle top.

Picture of a card of J-B Weld Steel Reinforced Epoxy High Temperature Glue, Front View.
J-B Weld Steel Reinforced Epoxy High Temperature Glue

Sandpaper for Electric Kettle Repair

This compound requires that the surfaces are dry, clean, and rough.  So we sanded the outer rim part of the black handle, as well as the mating areas of the lid. We used 3-M sandpaper for this, pictured next.



Picture of a package of 3M Sandpaper, 80 Grit, for electric kettle repair.
Electric Kettle Repair: 3M Sandpaper 80 Grit

Electric Kettle Repair: Prepare the Parts for Gluing

We sanded the highlighted regions of these parts, as shown below.  Then, we rinsed both pieces in water, dried them with a hand towel, and let them sit for an hour or so to be sure that they had completely dried.

Picture showing the areas to glue on broken kettle lid and handle.
Areas to glue on broken kettle lid, highlighted in green.

Here are pics of the pieces after sanding and drying, with green highlighting, illustrating exactly where sanding was done.

Picture of the sanded areas on the broken metal lid part.
Sanded areas on the broken metal lid part.



Picture of the broken handle Part of the kettle lid, roughed up via sanding.
Handle Part of Lid, Roughed Up Via Sanding

Mix Up the Epoxy

Next, we mixed the epoxy on a piece of old cardboard, as pictured next, starting with equal parts of the hardener and the steel.  Then we used an old bread bag tie to stir it up.  Note the dark gray color in the mixed potion.

Picture of the J-B Weld Hardener and Steel solutions, prior to mixing on an old piece of cardboard, for electric kettle repair.
J-B Weld Hardener and Steel, prior to mixing, for electric kettle repair.
Picture of the J-B Weld, Cold Weld Epoxy, with hardener and steel mixed together.
J-B Weld Cold Weld Epoxy, Mixed.

Spread the Glue Around, Generously

Then, we spread the mixed epoxy on the surfaces of the parts to be bonded, as illustrated in the images below.  We used that same bread bag tie as a spreader.

Picture showing the J-B Weld Steel Epoxy, Applied to Metal Lid Part
J-B Weld, Applied to Metal Lid Part
Picture of the J-B Weld Steel Epoxy, Applied to the broken handle part.
J-B Weld, Applied to Handle Part.

Electric Kettle Repair: Press the Pieces Together

Next, we pressed the handle and lid pieces together, and wiped off any excess epoxy with an old rag.  It’s important to remove any glue before it sets.  So we were quick about it.



Picture of the plastic handle and stainless steel lid, pressed together, glued, and wiped clean.
Repair Electric Kettle: Plastic handle and stainless steel lid, pressed together, glued, and wiped cleaned.

Clamp and Wait

Next, we set the assembly aside for 24 hours, to allow the epoxy to fully set, bond, and cure.  It bonded quite well.  To be safe, we waited a day or two longer before using the pot.  But after that wait period, we got full use of our Hamilton Beach electric cordless kettle back.  We succeeded in our first electric kettle repair.

Picture of the Hamilton Beach 40891 Cordless Electric Kettle, showing it fully assembled.
Repair Electric Kettle: Hamilton Beach 40891 Cordless Electric Kettle, showing it fully assembled.

See our   Hamilton Beach 40891 Cordless Kettle Review   piece for more details about this little electric water boiler.

Suggested Reading




References

Revision History

  • 2018-03-02: Then, updated the title and the tags list.
  • 2015-11-29: Next, added appropriate tags.
  • 2015-09-23: Then, added the Suggested Reading section and also, more tags.
  • 2014-12-06: Originally published.