Well I got the new element - it was the 27inch one - it is now fitted and working ok. But you are correct, and I was a bit lucky! I can see that there are many possible pitfalls and that some luck is needed. First of all (spot on, Adam) there was an isolation valve between the header tank and the cylinder - but the damn thing didn't work (not until some banging, WD40 and lots of heat were applied anyway!).
Then came the actual job of getting the old one out - and it was a very old one! - the cylinder was replaced in 1996, but I think that the immersion element was much earlier and had been re-used. First of all the proper box spanner that I got wasn't a very good fit - it was too big, I think that the element flange hexagon was an imperial size. I had sprayed WD40 on it some hours earlier - as recommended here, but I didn't have time to give days as advised. Even after wedging the box spanner to get a decent fit, and tapping it with a hammer, it still wouldn't budge.
Thankfully, after using the heat gun on it for a fair time (choking myself on fumes from the cylinder lagging and setting off the smoke alarms in the process!) I got it to move - hurrah! As I took it out I was surprised to find the cylinder full to the brim - even though I had the isolation valve closed and the hot taps open (with no water coming out of them). By placing a couple of towels around the immersion heater hole and gently pulling it out, I was able to clean up around the fitting and put the new element in place without there being much water splashing about.
Yep, I think it could be a real sod of a job if things went badly wrong on you. As it was I had real visions of having to replace the entire cylinder - at around £200, not to mention loads of work and hassle - not a pleasant prospect. Very grateful that it's done - and many, many thanks once again to everyone for their help.
If I could pass on one or two tips on the basis of this experience, I would say that:
- Make sure that the isolation valve (if there is one) supplying the cylinder is functioning ok before you start.
- Tie up the ball valve of the expansion tank in the loft as a precaution - better than turning off the cold water supply to the whole house (could be while before it can be turned back on again!).
- If your plumbing is quite old (like mine!), and things like stop taps and isolation valves haven't been disturbed for a while, it might be worth having a pipe freezer kit on stand-by.
- Make sure that you have plenty WD40 and a heat gun available.
- If the old element is quite stubborn to shift, and you need to give it a few bangs with a hammer, make sure that the cylinder is full of water to lessen the chances of damaging it.
- Best of luck - you might need it!