Break in the nichrome wire

The glowing wire is called nichrome wire (for nickel-chromium), if part of the
array does not heat there's a break in the wire somewhere.

Possible causes of breakage:

1) there was a weak spot or nick in the wire when the wire was manufactured,

2) there was a weak spot or nick made in the wire when the toaster was
manufactured (we've seen the break at or near a bend in the wire or a rivet
point)

3) someone physically broke the wire by sticking something (like a fork) into the
toaster.

An example of a nichrome wire break.

To Fix: You have to disassemble the toaster sufficiently to locate the break and
then get good access to it. If you're lucky and there's enough extra wire, you
might simply be able to twist the two broken ends together enough to re-
establish contact (you can then at least confirm that's the problem.)
In the photo, we were able to short across one wrap of the nichrome a re-
establish connectivity.

Otherwise, you need a high-temperature crimp and a crimping tool to to crimp

the two ends together. Here are two examples of crimps: High-Temperature
Crimp-on Butt Splice, Noninsulated, 22-18 Awg, 900 Degree F Temperature
Rating, Packs of 100 and High-Temperature Crimp-on Butt
Splice, Noninsulated, 16-14 Awg, 900 Degree F Temperature Rating, Packs of
100

Note: The nichrome wire is wrapped around sheets of a brittle ceramic/mica-like

material. Depending on where the break is you might find it necessary (or at
least tempting) to cut this material. Be very careful, sawing might be better than
cutting as it tends to flake.