When working on or using old lights, safety is an important consideration. Plastic parts often turn brittle with age, resulting in cracked sockets.
Although most light sets met the safety standards of the day when first sold, they may not meet present-day standards, which are stricter.
For example, most early light sets were not fused. I you want to enjoy such an old set you have two options: use a fused extension cord, available at any of the better Christmas supply outlets, or plug it into the END connector of a modern fused light set.
I also recommend using old sets only on artificial trees, which usually are fire-retardant.
Finally, repairs other than replacing bulbs should be done only if the set is irreplaceable.

A split socket on a miniature light set. This was a common problem with NOEL reflector sets. It will be repaired using heat shrinkable plastic tubing. Here's how.

"Shrink Tubing" is used extensively in the electronics industry and is a lifesaver.
You can buy it at any good electronics supply outfit.
An internet search using the term "Heat shrink tubing" should return several matches.
A few are "All electronics corp.", "cable ties plus" and "NTE electronics"

Here's what you will need.
3/8 Inch heat shrinkable plastic tubing in clear or green.
A heat gun or a butane lighter.
Utility knife.

Here's what you should do:
Before beginning work on a light set, make sure it is unplugged ! (I don't want any accidents)
Remove the bulb and cut a piece of tubing about 7/8 to 1 inch long, then place it on the socket.
Heat the tubing to shrink it using a heat gun, or if using a butane lighter, hold it so the flame tip
is 1 inch below the shrink tubing. Be careful not to overheat the tubing - you could melt the socket.
After the tubing has cooled, trim any excess with a utility knife - Watch your fingers !
Reinstall the bulb.
Repeat for any other split sockets you may find. Your set is now safe to use again.

Cut and place the tubing	Shrink the tubing	Trim the excess	The completed repair

Modern Miniature bulbs are slightly different from the old versions.
The filament is strung vertically to eliminate kinking and hot spots, and the wires of the bulbs are shorter.
Unfortunately, they may be too short to be used in old reflector/wedge bases, so it will be necessary to modify the wedge base to accept the new bulbs.
Using a utility knife, carve out a V into the exit holes of the wedge base.
You only need about 1/8 inch of extra lead length so just take off a little bit of plastic. See the illustration below for guidance.
Now thread the wires of the new bulb into the holes of the modified base and they should just fit.

Using a light dimmer to test miniature light sets.

A valuable piece of equipment for testing miniature Christmas light strings is a variable AC supply, or dimmer switch.
Such a device allows you to gradually increase the voltage applied to the set to check for defects.
There are two types of variable AC supplies and each has its advantages and disadvantages.

(Click photo to enlarge) Typical triac dimmer switch by Hexacon electric Co. This device reduces output voltage by "chopping" the AC waveform, allowing only part of the cycle to pass. This model includes a panel meter for monitoring the AC output voltage. Advantages: Low cost, light weight. Disadvantages: Triac regulator may be damaged if connected to short circuit. Only capable of supplying decreased output voltage.

(Click photo to enlarge) Typical variable transformer. This model has two switches for adjusting the output from 25 volts AC to 150 volts AC in 5 volt steps. Advantages: True AC output waveform isolated from input. Capable of supplying increased and decreased output voltage. More tolerant of short circuits. Disadvantages: More expensive, heavier than triac dimmer.

What do you do when you plug in a set of miniature lights and one of the strings, or the entire set, doesn't light?
Just follow these instructions to get the set to light again.
First, check the fuses.
If any of the bulbs light up, then the fuses are good. If no bulbs light up, remove the fuses and test. Or, plug a known good mini set
into the END connector, if there is one. If that set lights, the fuses are good.
Modern sets of the 1990s and later have replaceable fuses. Sets made in the late 1970s to 1990 had fixed ,non replaceable fuses,
and sets made before 1977 had no fuses.
Next, check the flasher bulbs.
Some mini sets use special flasher bulbs to make the string twinkle. Each string will have a flasher, and they are either clear, or red-tipped.
A flasher bulb has an extra flat metal strip, called the Bi-metal strip, that makes it flash. Eventually you'll learn to recognize them.
Remove these bulbs, test and replace as needed. If the set now lights, that was the problem.
Now check the remaining bulbs.
For this task you'll need a proximity tester, a device that senses A.C. Voltage in the wires. An example of one is shown below.
Starting with the first bulb in the string, place the probe next to the socket. The L.E.D will either light, (showing voltage is present), or not light.
Continue down the string until you find the place where the L.E.D. goes out (or comes on) this is where the bad bulb is.
Remove both adjacent bulbs and test and replace as needed. You may find several bulbs burned out.
You may even find that all of the bulbs are burned out. This is known as a cascade failure and is the ultimate result of not replacing burned out bulbs promptly!
Obviously you'll need to replace all of the bulbs in that string. This is what after-Christmas sales are for!

A typical proximity tester for miniature Christmas Lights. This model also has contacts to test fuses and bulbs.

A 1970s era Midget Bulb Tester which is now obsolete. This simple device used a 9 Volt Transistor battery to test wedge base bulbs.

  How does that shunt device work?

If you've ever examined a miniature bulb under a magnifier, you've probably noticed a coil of fine wire wound around the filament posts.
Yes, that is the shunt device, and I'll explain how it works. When the light set is operating properly, the voltage across any one bulb will be the line voltage divided by the number of bulbs in the string. For example, for a 50 light string run on 120 volts, each bulb gets 120/50 =2.4 volts.
At this low voltage the shunt does not conduct.
But what happens when a bulb burns out? When that happens the filament becomes an open circuit and the full line voltage appears across that bulb.
This voltage surge is what activates the shunt. The shunt coil now becomes a short circuit across the filament wires and current flows again, which keeps the remaining good bulbs lit. The shunt device is similar to a Metal Oxide Varistor (M.O.V.) because it only conducts when the voltage across it rises above a threshold level.

Selecting the correct replacement bulb for series wired mini sets is difficult because the voltage AND current ratings are important.
Use this chart which covers most 5.5 millimeter miniature bulbs from the past 40 years, as a guide for finding the right bulb for your set.
It assumes a line voltage of 110 Volts. Thankfully, modern sets from the past 10 years are more standardized.

Notes : Bulb current is read in milliamps (1000 ma = 1 amp).
 Note 1 : 6 and 7 Volt /125 ma bulbs used in reflector sets are no longer available.
If you substitute 60 ma bulbs you MUST replace all the bulbs in the string.
Note 2 : Bulb current is reduced in modern bulbs to meet safety standards limiting power usage and subsequent heat generation.
 Note 3 : 12 and 13 Volt /90 ma bulbs used in reflector sets are no longer available.
If you substitute 60 ma bulbs you MUST replace all the bulbs in the string.

Always replace burned out bulbs promptly to prolong the life of the remaining bulbs.
To determine the bulb voltage, first check the instructions on the back of the box, if you still have it.
  Then check any tags that may be attached to the string.
Here's a trick you can try. Remove one bulb from a working section of the set and then count how many bulbs go out.
  If 50 bulbs go out, then you need 2.5 volt bulbs. If 35 bulbs, it's 3.5 volt. If 20 bulbs, it's 6 volt. If 10 to 12 bulbs, you need 12 volt.
When you install a replacement bulb, it should light with about the same brightness as the other bulbs in the string.
  If the new bulb is much brighter or dimmer, you probably have the wrong bulb.
  You may need to try different brands of bulbs to get the best match in brightness compared to the others.
If you find more than half of the bulbs in a string are burned out, you should replace all of the bulbs as the remaining
  good bulbs will be severely stressed and will only last a short time anyway. (known as re-lamping)
If you are re-lamping a set try to use all of the same brand of bulbs as different brands often have slightly
  different voltage/current ratings. This could cause one brand to burn out faster than the other.
Old sets may use bulbs which are now obsolete. The only option is to replace all bulbs with modern equivalents.
  Just be sure to use bulbs with the same or higher voltage rating.
On sets used outdoors, the fine pigtail leads of the bulbs sometimes break due to vibration and/or corrosion.
 This will cause the entire string to go out.

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