In case you're interested, I gave it a bit more time in the oven, and this evening fired it up again, and the RCD didn't trip.
I assembled the whole thing, and after a couple of minutes it tripped the RCD again, but it was like an old car spluttering into life: it took three or four more attempts, and then once on it stayed it on.
I ran a few test and cleaning cycles - no leaks or problems anywhere - and then it made one of the nicest cups of espresso I've had from it. Not bad for a machine that age that's had so much use.
Probably the previous owner (it was already several years old when I bought it nearly five years ago) never ran a cleaner or descaler through it, but it's working now better than ever before.
Added bonus: I now thoroughly understand the (pretty simple) electrics and mechanics, and it's really nice to have something that I can maintain and keep working indefinitely. Gaggia Classic for the win, as the young people say nowadays.
or so before any failure. As soon as you see any glowing its more than hot enough to drive out any water and burn off any carbon deposits.
in a metal tube. The worst failure I've seen arced and melted part of the outer tube, then popped a fuse.
Two things, one I have seen an element blow, producing a split and a shower of white powder. Second, the housing looks aluminium which would likely melt before it glowed red hot, more likely in daylight. Given the difficulty in getting a replacement element I wouldn't take the chance.
I would rather connect the unit up and put oil in the container to limit temperature rise, making sure that the housing wasn't earthed, if necessary by temporarily removing the earth from the plug.
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