How to Restore How to Restore Your Your

TubeTube RadioRadioA Paul Pinyot, Solder Smoke and Burnt A Paul Pinyot, Solder Smoke and Burnt

Finger presentation at,Finger presentation at,

W3KWH W3KWH Steel City Amateur Radio ClubSteel City Amateur Radio Club

August 8August 8thth 7:30pm 7:30pm

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Let’s get Cookin’Let’s get Cookin’

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ScheduleSchedule March 7, 2012 Open to all! March 7, 2012 Open to all! Kick off. This Kick off. This

presentation and preparation discussion.presentation and preparation discussion. March 8 through 27. March 8 through 27. Acquire your radio and Acquire your radio and

service documentation service documentation (see presentation).(see presentation).

March 28 pick parts and test tubes. March 28 pick parts and test tubes. I will I will bring a tube tester, parts bins bring a tube tester, parts bins (capacitors, resistors, lamps)(capacitors, resistors, lamps) for you for you to purchase replacement parts at my cost to you.to purchase replacement parts at my cost to you.

April 4 and 25, and May 2. April 4 and 25, and May 2. Continue restoration Continue restoration at NHARCat NHARC..

May 17-20 May 17-20 Dayton Hamvention.Dayton Hamvention. May 23 May 23 electronic alignment. (see presentation).electronic alignment. (see presentation). End of project. End of project.

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What you need to What you need to COMPLETECOMPLETE your projectyour project

An understanding of electrical safety and An understanding of electrical safety and hazards. hazards.

A radio and new replacement components A radio and new replacement components Service documentationService documentation (schematic, alignment data). (schematic, alignment data). A moderate to high soldering skill levelA moderate to high soldering skill level Hand tools including:Hand tools including:

Soldering iron >=25w, rosin core solder, small wire cutters, Soldering iron >=25w, rosin core solder, small wire cutters, Needle nose pliers, screw driversNeedle nose pliers, screw drivers

Extension cord for activities at NHARC meetings.Extension cord for activities at NHARC meetings. Optional “lead wire twister” Optional “lead wire twister” (see presentation).(see presentation). An assortment of other non specified hand tools are An assortment of other non specified hand tools are

helpful. helpful.

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What you need cont’.What you need cont’.Contact cleaner and light lube oil.Contact cleaner and light lube oil.A copy of the steps in this presentation.A copy of the steps in this presentation.About 8 to 16 hours for a five tube radio. About 8 to 16 hours for a five tube radio. About 10 to 40 hours for > five tube About 10 to 40 hours for > five tube

multi-band consumer radio chassis. multi-band consumer radio chassis. Work at home commitment.Work at home commitment. There will There will

NOT be enough time at NHARC meetings to NOT be enough time at NHARC meetings to complete a restoration. complete a restoration.

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Beyond this project’s scopeBeyond this project’s scopeCabinet RestorationCabinet RestorationCommunications gear including but Communications gear including but

not exclusive to:not exclusive to:Receivers like Hammarlund, Collins, Receivers like Hammarlund, Collins,

Hallicrafters (except the S-38 line and Hallicrafters (except the S-38 line and similar).similar).

Transceivers.Transceivers.Transmitters.Transmitters.Hybrid gear (transistors, IC).Hybrid gear (transistors, IC).

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Steps to restorationSteps to restoration

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Steps to restorationSteps to restorationLocate your radio.Locate your radio.Find documentation before Find documentation before

purchasing.purchasing. Inspect and photograph (before Inspect and photograph (before

restoration).restoration).Test for operationTest for operationDisassemble and save all partsDisassemble and save all partsCold test all Transformers and coils. Cold test all Transformers and coils. Test all tubes. Test all tubes.

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Order replacement tubes and other Order replacement tubes and other long lead items.long lead items.

Shine up chassis if so desired.Shine up chassis if so desired. Inspect wire insulation. Replace power Inspect wire insulation. Replace power

cord.cord.Acquire capacitors, resistors and lamps.Acquire capacitors, resistors and lamps.Lay out copy of schematic including red Lay out copy of schematic including red

and green pencilsand green pencilsReplace capacitors Replace capacitors Replace resistorsReplace resistorsOpen IF cans and replace resistors.Open IF cans and replace resistors.

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Replace power cordReplace power cordClean controls and switchesClean controls and switchesDim bulb test your work then direct Dim bulb test your work then direct

to line.to line.AlignmentAlignmentBurn-in for => 8hoursBurn-in for => 8hoursCheck alignmentCheck alignmentClean cabinetClean cabinetReturn to cabinet and enjoy.Return to cabinet and enjoy.

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Locate your radio.Locate your radio.eBay is popular.eBay is popular.Ham fests.Ham fests.Flea markets.Flea markets.Garage/Estate sales.Garage/Estate sales.Family.Family.

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Find documentationFind documentationhttp://www.nostalgiaair.org/Resourcehttp://www.nostalgiaair.org/Resource

s/s/Domestic US consumer radios.Domestic US consumer radios.

http://www.radiomuseum.org/http://www.radiomuseum.org/ For European and some domesticFor European and some domestic

http://bama.edebris.com/manuals/http://bama.edebris.com/manuals/Boat anchors/test gearBoat anchors/test gear

http://www.ppinyot.com/HomePage.hhttp://www.ppinyot.com/HomePage.htmtmFor more links and resources.For more links and resources.

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Inspect and documentInspect and document

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Inspect and documentInspect and document One picture is much better than your (my) One picture is much better than your (my)

memory. Take lots of pictures. This is how memory. Take lots of pictures. This is how most of my web site pictures are captured. most of my web site pictures are captured. Simply as a record of what went where. Simply as a record of what went where.

The cheapest digital camera is better than no The cheapest digital camera is better than no camera at all.camera at all.

Macro capability is great. Or hold a surplus Macro capability is great. Or hold a surplus macro lens in front of a digital camera with macro lens in front of a digital camera with out macro capability. It works. Believe me. out macro capability. It works. Believe me.

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Test for operationTest for operation This step saves a lot of time. If you can This step saves a lot of time. If you can

hear the faintest of transmitters then most hear the faintest of transmitters then most if not all of your tubes, oscillator coils, if not all of your tubes, oscillator coils, chokes, IF transformers, Audio Output chokes, IF transformers, Audio Output Transformer, speaker, band switch, Transformer, speaker, band switch, volume pots and many more things are volume pots and many more things are working. working.

Use a Variac set-up or a Dim Bulb Tester Use a Variac set-up or a Dim Bulb Tester (DBT) to protect the parts made from (DBT) to protect the parts made from Unobtainium.Unobtainium.

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Dim Bulb TesterDim Bulb Tester Current limiting Current limiting

device.device. A “Must Use” on all A “Must Use” on all

restored chassis.restored chassis. To make and use To make and use

one see: one see: http://www.ppinyot.cohttp://www.ppinyot.com/dimbulb/dim_bulb_tm/dimbulb/dim_bulb_tester.htmester.htm Alternative:

Variac plus an amp meter plus a volt meter.

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HOT Chassis!HOT Chassis!

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Hot switchedHot switched

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Neutral switchedNeutral switched

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DisassembleDisassemble Take the chassis out. Pulling off the knobs Take the chassis out. Pulling off the knobs

can be a challenge. They are often held on can be a challenge. They are often held on with set screws and rust.with set screws and rust.

Have Zip Lock bags available and a sturdy Have Zip Lock bags available and a sturdy cardboard box. cardboard box.

The box will help protect your glass tubes.The box will help protect your glass tubes. Wrap and tape the speaker with cardboard. Wrap and tape the speaker with cardboard.

I have put too many screwdrivers through I have put too many screwdrivers through paper cones. It will make you sick. paper cones. It will make you sick.

Take pictures too. Take pictures too.

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Cold test all Transformers and Cold test all Transformers and coilscoils

If you had a successful DBT test you If you had a successful DBT test you can skip this step.can skip this step.

Use an ohm meter to DC test the coils, Use an ohm meter to DC test the coils, transformers, speaker for continuity. transformers, speaker for continuity.

Mark off (highlight) these items in Mark off (highlight) these items in green on your schematic. green on your schematic.

Schematics often have a DC Schematics often have a DC resistance on the coil schematic. resistance on the coil schematic.

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Test all tubesTest all tubes It helps to have all tubes tested. A It helps to have all tubes tested. A

weak tube can throw you for a loop. weak tube can throw you for a loop. Most tubes will be fineMost tubes will be fineGuitar amp tubes take a beating. Guitar amp tubes take a beating. AA5 audio (50C5) and rectifier tubes AA5 audio (50C5) and rectifier tubes

(35w4) take a beating too. Look for (35w4) take a beating too. Look for hot shorts in the rectifier tubes.hot shorts in the rectifier tubes.

Put the tubes back into the chassis or Put the tubes back into the chassis or use duds in place. More on this later. use duds in place. More on this later.

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Order long lead itemsOrder long lead items

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Order long lead items.Order long lead items.

This is rather self explanatory.This is rather self explanatory. Order needed tubes.Order needed tubes. Grill clothGrill cloth Rebuild crystal cartridges/idler wheelsRebuild crystal cartridges/idler wheels Re-cone speakersRe-cone speakers Special caps and high watt resistorsSpecial caps and high watt resistors Send off cabinet to refinisher.Send off cabinet to refinisher. etcetc

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Shine up chassis if so desired.Shine up chassis if so desired. PROTECT or remove the variable air PROTECT or remove the variable air

condenser (Tuning gang capacitor) !!!condenser (Tuning gang capacitor) !!! Lots of manual labor and elbow grease.Lots of manual labor and elbow grease. See: See: http://www.ppinyot.com/P/shiny_chassis.htmhttp://www.ppinyot.com/P/shiny_chassis.htm

for ideas. for ideas.

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Inspect wire insulationInspect wire insulation

kB3URN

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Inspect wire insulationInspect wire insulationMany radios manufactured during WWII Many radios manufactured during WWII

has rubber insulation that does not last. has rubber insulation that does not last. It is hard as sugar candy or soft and It is hard as sugar candy or soft and gooey as chewed bubble gum. gooey as chewed bubble gum.

It needs to be replaced or covered with It needs to be replaced or covered with “spaghetti” or heat shrink insulation.“spaghetti” or heat shrink insulation.

Replacement is the desirable solution.Replacement is the desirable solution.Heat shrink over transformer leads is Heat shrink over transformer leads is

second best. second best.

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Inspect wire insulation Inspect wire insulation continued.continued.

Spaghetti is third.Spaghetti is third.Avoid paint on insulation. Thickness Avoid paint on insulation. Thickness

is not controllable. is not controllable. Keep a tube in all the sockets. This is Keep a tube in all the sockets. This is

where socket breakage is high!where socket breakage is high!Use 600 volt UL rated insulation. Use 600 volt UL rated insulation. Use stranded for any connection off Use stranded for any connection off

of the chassis (i.e., speaker, dial of the chassis (i.e., speaker, dial lamps, antenna, etc). lamps, antenna, etc).

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A Tube Socket storyA Tube Socket story

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A Tube Socket storyA Tube Socket story A broken tube socket degrades the A broken tube socket degrades the

performance of a radio. Dust and dirt performance of a radio. Dust and dirt accumulate and cause a short. Once an accumulate and cause a short. Once an arc has occurred a carbon track is laid arc has occurred a carbon track is laid down. It is very hard to remove all the down. It is very hard to remove all the carbon and replace with a high insulation carbon and replace with a high insulation material.material.

Put a tube into any socket before soldering Put a tube into any socket before soldering or de-soldering any pin connector!or de-soldering any pin connector!

Practice this preventative measure and all Practice this preventative measure and all will live happily ever after. will live happily ever after.

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Acquire capacitors, resistors and Acquire capacitors, resistors and lampslamps

Most schematics have a list of parts. Most schematics have a list of parts. Electrolytic and paper containing capacitors Electrolytic and paper containing capacitors are a priority for replacement. Mica and are a priority for replacement. Mica and ceramic caps are good to keep.ceramic caps are good to keep.

Use 630 volt polypropylene (<1 uf) Use 630 volt polypropylene (<1 uf) capacitors in all positions (unless a higher capacitors in all positions (unless a higher voltage is needed).voltage is needed).

Use 450 volt Electrolytic capacitor in the Use 450 volt Electrolytic capacitor in the power supply (160 volts for AA5)power supply (160 volts for AA5)

I will bring my parts bins to pick your parts. I will bring my parts bins to pick your parts. (Your $ cost will be my $ cost. No mark-ups.)(Your $ cost will be my $ cost. No mark-ups.)

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Tubular Axial Capacitors

                                    

Metalized Polypropylene FilmGood replacement for Wax/paper caps. Metalized Polyester FilmSelf-healing property

Orange Dips

                             

Metal-Foil Polypropylene Film •Orange epoxy coated for superior heat, solvent and moisture resistance. •Excellent stability for High Current / High Frequency / Temp. Compensation Applications.

Metalized Polyester Film

•Highly reliable with "self-healing" performance

500 Volt Dipped Silver Mica Capacitors

                

1 pF to 5000 pF,

Electrolytic CapacitorsY2 Safety and

Interference Suppression Capacitors

Line to Line (X) and Line to Chassis.

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Micamold & “Black Beauties”Micamold & “Black Beauties” Mica Mold is a company Mica Mold is a company

that made nano and that made nano and pico farad capacitors pico farad capacitors that look like mica or that look like mica or ceramic “domino” ceramic “domino” capacitors. But they capacitors. But they used paper. used paper.

These capacitors must These capacitors must be replaced!be replaced!

““Black Beauties” or Black Beauties” or “Bumble Bee” “Bumble Bee” capacitors also have capacitors also have paper inside and MUST paper inside and MUST be replaced. be replaced.

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Acquire capacitors, resistors and lamps Acquire capacitors, resistors and lamps continued.continued.

Most carbon composition resistors are bad. Most carbon composition resistors are bad. If not now they will be later after getting hot. If not now they will be later after getting hot. They have been sitting absorbing moisture They have been sitting absorbing moisture and thermal cycling for decades of non use. and thermal cycling for decades of non use.

Just replace them now and avoid the failures Just replace them now and avoid the failures later. later.

Use ½ watt 5% Carbon Film resistors. Use ½ watt 5% Carbon Film resistors. Use new Carbon Composition for circuits Use new Carbon Composition for circuits

operating over say 18 MHz (HF).operating over say 18 MHz (HF). Do NOT use New Old Stock (NOS) carbon Do NOT use New Old Stock (NOS) carbon

composition resistors. They go bad on the composition resistors. They go bad on the shelf.shelf.

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Carbon Film 1/2 w 5% about $0.07

•Watch for inductance.•High quality performance at economical prices •1/2 & 1 Watt •General shotgun replacement.

Carbon composition ½ w about $0.20

•Use above 18 MHz•5 % tolerance •Low inductance •Low capacitance

Metal Film ½ w about 11 cents

1 % tolerance •Epoxy coated precision resistors

• 5 % tolerance •Power Supply section.•Cathode Bypass•Candohm replacements

Metal Oxide 1 and 2 watt 12/17 cents

POWER Resistors Wire Wound very inductive.

5 watt $0.37Power SuppliesCandohm replacements

10 watt $0.50AKA Sand, cement, Ceramic, wire wounds

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Lay out copy of schematic with red Lay out copy of schematic with red and green pencilsand green pencils

Mark off or Highlight Mark off or Highlight components in Red components in Red when replaced. when replaced.

Trace the connections Trace the connections in green to verify the in green to verify the circuit is original circuit is original factory design. factory design. Undocumented, Undocumented,

unapproved, mods were unapproved, mods were made to gear when made to gear when parts were not available parts were not available (war time) or the shop (war time) or the shop was too cheap to was too cheap to properly repair the fault. properly repair the fault.

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Replace capacitorsReplace capacitors Replacing the capacitors Replacing the capacitors

first will give you more first will give you more room to replace other room to replace other parts.parts.

Use hook and crimp Use hook and crimp method. This makes for a method. This makes for a fast and strong fast and strong replacement. It also more replacement. It also more importantly keep the part importantly keep the part in the same relative place in the same relative place as the original.as the original.

The performance of The performance of plenty of radios is plenty of radios is affected by parts affected by parts placement and wire dress.placement and wire dress.

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Replace resistorsReplace resistorsUse the hook, crimp and solder Use the hook, crimp and solder

method.method.A Lead Twister tool is really helpful A Lead Twister tool is really helpful

with resistor replacement. with resistor replacement.

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Lead TwisterLead Twister A lead twister adds little A lead twister adds little

coils to the lead wires of coils to the lead wires of the new parts. the new parts.

Cut out the original part Cut out the original part near the body.near the body.

Slip the new part’s coils Slip the new part’s coils over the old lead wires and over the old lead wires and solder. solder.

This maintains the original This maintains the original component position and component position and makes for a quick secure makes for a quick secure solder joint.solder joint.

See: See: http://www.ppinyot.com/leahttp://www.ppinyot.com/lead_twister.htm to make one. d_twister.htm to make one.

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Open IF cans and replace Open IF cans and replace resistorsresistors

See: http://www.ppinyot.com/if_transformers.htm

Sliver Mica disease (AA5) Replace Resistors

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Hot test restored chassisHot test restored chassis

Please use a dim bulb tester…….

4343

Hot test restored chassisHot test restored chassisUse a Variac, volt and amp meter OR Use a Variac, volt and amp meter OR

DBT. Once passed then plug directly DBT. Once passed then plug directly into the line (mains). into the line (mains).

Tune in a strong station on Broadcast.Tune in a strong station on Broadcast.More than likely you will hear a More than likely you will hear a

station or more.station or more. If you are lucky the dial frequency If you are lucky the dial frequency

may be close. may be close.

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AlignmentAlignmentGet alignment data.Get alignment data.Warm up RF generator and Warm up RF generator and

frequency counter. frequency counter. Connect voltmeter to AGC or AC Connect voltmeter to AGC or AC

meter to speaker terminals.meter to speaker terminals.Perform AlignmentPerform Alignment

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Trouble?Trouble? If the DBT passes trouble shoot after If the DBT passes trouble shoot after

your first alignment. The IF your first alignment. The IF transformers could be so far off the transformers could be so far off the radio will not receive. radio will not receive.

If still dead use appropriate trouble If still dead use appropriate trouble shooting techniques to repair. shooting techniques to repair.

4646

AlignmentAlignment I will bring alignment gear. I will bring alignment gear. Follow the alignment procedures.Follow the alignment procedures.An RF generator with AM modulation is An RF generator with AM modulation is

commonly required. commonly required. A Frequency meter (or general coverage A Frequency meter (or general coverage

receiver) is needed to set the RF gen. receiver) is needed to set the RF gen. Burn in the radio 4 to 8 hours.Burn in the radio 4 to 8 hours.Perform the alignment again. Perform the alignment again.

4747

Put it all back together.Put it all back together.Clean your cabinet.Clean your cabinet.Make cosmetic improvements. Make cosmetic improvements. Check for electrical safety again.Check for electrical safety again.String up an antenna and enjoy your String up an antenna and enjoy your

new old radio.new old radio.

4848

Hotel Radio 6AHotel Radio 6ADetrola 576Detrola 576

4949

5050

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5252

Thank YouThank You

5454

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Objective and GoalsObjective and GoalsMake an old tube radio chassis work Make an old tube radio chassis work

good again. good again. There will be minimal cabinet There will be minimal cabinet restoration techniques covered or suggested. restoration techniques covered or suggested.

To get hands on practical experience To get hands on practical experience with old radio technologywith old radio technology

Enjoy listening to the product of your Enjoy listening to the product of your Hands-On efforts. Hands-On efforts.

Have fun!Have fun!