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Posts Tagged ‘restoration’

Esteemed Bose® Model 901 Active Equalizer – Serial #230 Repair

October 17, 2014 2 comments

Cross-posted from Rain City Audio:

I had the distinct pleasure of working on one of the earliest  Bose® Model 901 Active Equalizers from Series I’s first production run. Serial #230, in fact! It’s made entirely by hand and shows traces of hand re-work as the design was being tweaked – really a piece of history!

This particular equalizer was a gift from Dr. Amir Bose himself to its current and only owner as an undergrad on a factory tour in the early ’70s, and after a lifetime of enjoyment it was time for a rebuild.

Incredibly, this one still has the “Acoustic Suspension Loudspeaker” decal in the center of the treble contour knob.

The owner reported it was having several issues, and opening it up one problem was obvious: the bass contour inductors had broken free of their mounts and were rattling around inside.

It was fairly similar to the later Series 1 Early boards I’d serviced, but had different style inductors and a few extra jumper wires.

It did have discrete Zener diodes installed instead of the reverse-connected transistors. And as for the transistors – the early production models used the 2N3393, and on this one they were so worn out they were only delivering about 20% of their normal gain tested out of circuit. That’s definitely no good!

It cleaned up very nicely, though:

This equalizer is restored back to full performance for its owner to enjoy for another few decades. With all new Nichicon Fine Gold electrolytic capacitors, 1% resistors, new miniature wirewound inductors, rectifier diodes, transistors, Zeners, and a thorough switch cleaning this one is good as new and will sound great for a long time to come.

Rain City Audio Bose® Active Equalizer Repair

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1934 RCA Victor 119 Antique Radio Repair

April 23, 2014 Leave a comment

I just finished a new project over at Rain City Audio – 1934 RCA Victor 119 Antique Radio Repair

An example of the 1939 RCA Model 119 radio made its way through my shop recently. I like RCA’s engineering – they were pioneers of radio and even their entry level models like this set had great performance. The styling is classic mid ’30s, too – great in almost any home….

Check it out at http://www.raincityaudio.us/blog/1934-rca-victor-119-antique-radio-repair!

Oregon Electronic Model A3 Variable Voltage Regulated Power Supply

April 20, 2014 Leave a comment

Here’s another project I just finished at Rain City Audio:

This vacuum tube power supply from an engineer’s test bench can replace a radio or test circuit’s power supply to help with troubleshooting or experiments, with up to 400V for B+ and 6.3V 5A for the heaters. It needed some new capacitors, then fired right up and works perfectly!

Oregon Electronic Model A3 Variable Voltage Regulated Power Supply

1931 Westinghouse WR-8 Columaire Antique Radio Repair

April 14, 2014 Leave a comment

I recently got to work on another beautifully reconditioned Westinghouse WR-8 Columaire radio all the way from Bellingham. It was originally in for service with the SPARK Museum, but the repair technician reportedly suffered some health complications and was unable to complete the job so it came down to Seattle to finish it off. I’d previously worked on one of these back in 2013, but this one was in a bit better shape – although it took a long road to get there!

At some point in the past, the radio was badly damaged by an errant candle placed on top which must have fallen over and badly burned the top half of the radio. Afterwards, it was placed in a basement for many years and forgotten about, collecting moisture damage and dust along the way until being brought back out.

The owners spent a lot of time on the cabinet:

and reconing the speaker:

Then it was into the shop for the detailed electrical repairs!

All of the tubes in this radio tested brand new, and all the transformers and coils checked out, so it should be a pretty straightforward repair. Overwhelmingly, the resistors tested in spec also, only a few were slated for replacement. It’s been worked on before at one point, too:

An interstage transformer, normally potted in a top can, was replaced with an open-frame transformer from the late ’30s or ’40s, mounted under the chassis.

This model could be used with a phonograph or a remote control, although neither option was fitted on this model.

I began by mounting new terminal strips under the chassis, soldering them to the lugs on the old capacitor pack.

I took a slightly different approach for the other capacitor pack, using the existing phenolic board as the terminal strip after cutting off the pack capacitor.

For a size comparison, here’s a third capacitor pack containing only a single capacitor – and on top, its replacement, and a quarter for scale.

The owner requested something to make it easier to reset the clock when the time came: Molex connectors! I use 600V connectors with individual connections.

Not the prettiest, but it’ll work. The wire insulation was nicked in a few places, so I reinforced those areas with electrical tape.

Time to fire it up and test—loud and clear! I peaked up the alignment carefully and let it burn in for a while. The lead routing ultimately needed to be tweaked a little bit as there was some interference, but it was easily corrected.

After refitting both chassis and the speaker back into the cabinet, this Westinghouse was ready to go home and make warm, rich, beautiful music for many years to come.

What a beautiful piece! You’d never know how far it had to come to get to this shape. Bringing it back to life so nicely was a joint effort – without the owner’s dedication to the cosmetics of the cabinet, it would never have made it to the electrical stage.

If you need your antique radio repaired, Rain City Audio can help!




1946 Zenith 6-D-029 Consoltone Antique Radio Repair

April 7, 2014 1 comment

A local client just brought in a very interesting Zenith tabletop radio from just after WW2, the 1946 Zenith 6-D-029 Consoltone mantle radio. This is one of the iconic “boomerang” dials Zenith produced for a couple of years after the war. A variety of sets were made with similar styling; in this case the 6-D-029 is a 6-tube AC/DC radio with a combination of octals and loctal tubes.

This radio was repaired in the ’90s by a radio shop in Portland, OR but came to me in non-working condition. That’s not unreasonable for a radio to need another round of service after 20 years, and it looks like they did good work last time.

Checking out the tubes, other than one which was conveniently labeled (and testing confirmed) “weak”, they all had good filaments and good emissions. Something else was clearly the problem. Given the set’s owners don’t own a tube tester, the tube labeled “weak” must have been from the last time the radio was serviced; this one was the RF amplifier front-end tube.

It’s been pretty well cared for – the cabinet is in solid shape and there’s only a tiny amount of dust inside. Underneath, however…

There are several things going on here. Number one is somewhat obvious: something has released some smoke inside. In addition to that, the electrolytics used in this repair were different ages. There’s the blue CDE dual-section capacitor, and a Jamicon 33uF 450V capacitor hooked up as the second filter. Time to start pulling parts.

That Jamicon capacitor is visibly bulging from one side, and testing confirms it’s definitely dead. Of the CDE dual cap, one section was badly out of spec, and the other section tested open as well.

One of the ceramic disc capacitors blew itself apart – rather violently damaging a mylar capacitor near-by and generally making a mess of things. I replaced all of the same model of capacitor with new 630V film capacitors just to be safe.

After replacing the components it was time for the first power-up. No smoke! But, no sound either. Checking around on the voltages, something wasn’t quite right. B+ on the output tube was about 50% high, and there was no voltage on the screens of any tube.

Careful inspection and wire tracing got to the root of the problem: the wire between two tie points, supplying high voltage to the screens of the output tubes and the plate and screens of the RF and IF tubes, had broken at some point – likely from 68 years of metal fatigue. This was likely the root cause of the original failure: the ceramic disc capacitors were rated at 100V. With 4/6 tubes not conducting, the power supply was delivering over 160V when the nominal operating B+ was about 100V under load. This is well over the rating of those ceramic capacitors and could have caused the violent failure which took the radio out of service.

That’s more like it! A jumper confirms the issues has been located. The new capacitors are rated 630V, so should have no trouble with voltage spikes.

I soldered a 2″ segment of wire to make the connection permanently.

With that repair made, the radio fired up loud and clear!

Time to adjust the alignment a bit:

Then finally, back into the cabinet and ready to go home.

With all new film and electrolytic capacitors, and a replacement tube, this Zenith table radio is going to last a very long time before it needs to be serviced again and sound great the whole time.

If you need your antique radio repaired, Rain City Audio can help.

1940 Philco 40-185XF Antique Radio Restoration

April 2, 2014 Leave a comment

I had the privilege of working on a very well preserved Philco 40-185XF recently. These are top performing pre-war sets featuring 8 tubes, an RF amplifier front-end and push-pull audio output into a 12″ speaker. Definitely worth fixing up! This radio had been its owner’s family for years – first in his grandparent’s home, then with his parents, before it passed on to him. After serving as a conversation piece for many years, it was time to get it going again.

This model had been sitting silently since the 1970s and was ready to come back to life. It came to me for a complete overhaul, including testing all the tubes to replace as needed, re-stringing the dial, replacing hardened rubber mounts and eroded pushbuttons, and a precision alignment.

The underside is nicely laid out and pretty easy to work on. There’s a few capacitors which are buried, but most are easily accessible. The output transformer, top left, is mounted under the chassis instead of on the speaker as was more common on earlier sets.

Component replacement was initially pretty straightforward. The preset assembly was held in by two screws and had plenty of slack to fold it up and out of the way to allow easy access to the components beneath it. There were several small capacitors and an electrolytic can mounted under the pushbutton assembly.

The power cord was in dire need of replacement, so it received a new polarized plug and new X1Y2-rated safety capacitors on a newly mounted terminal strip.

With component replacement complete, it was time for a first power-up and a test signal. All seemed to be good at first for a bit…but then the radio sputtered a bit and cut out entirely – then some faint smoke started to appear! Bad, bad sign. I killed the power quickly to avoid damaging anything and carefully inspected the fault.

On this schematic snip, the resistor circled in red was the one which was overheating and smoking. This resistor feeds the high voltage to the front-end of the radio; overheating means excess current drawn. I pulled those tubes, but it continued to smoke, so further investigation was necessary. First, I replaced that resistor with a new one which hadn’t been heat-damaged.

It’s a bit faint, but the insulation had cracked off the wires leading into the IF can and were shorting to the chassis. That’d be the problem! Time to pull the IF can:

Some wires were cloth and some rubber-coated; some of the rubber coated ones were fine, and some were brittle and cracking. I sleeved the damaged wires, then reinstalled the transformer in the can and mounted it back up. One problem solved! The short circuit was fixed, but there was still no audio output – even when injecting directly into the audio amplifier circuit.

There were some clicks when I’d touch certain resistors with a probe. The resistors had overwhelmingly tested within tolerance so most were left original, but something happened along the way. I pulled the suspect resistors to replace, and examined the old one:

It’s tough to see – but the body of the resistor is cracked! This was a new problem. What happened is: carbon composition resistors absorb moisture from the atmosphere over time. In this case, the radio is 74 years old, and 44 of those years it sat without being played. Resistors also dissipate heat when they’re operating. This combination caused the absorbed moisture to expand and escape by cracking the body of the resistor and causing intermittent opens. Not good for performance! I replaced nearly all the remaining resistors at this point.

The replacements are 1% tolerance precision metal film resistors which should last for a very long time, and don’t absorb moisture the way carbon resistors do. Now, I was able to get audio, but no radio reception. Testing the front-end verified the radio was operating, but it wasn’t tuning a signal. Time to investigate the band switch – which, surprise, was badly gunked up! The mechanism wasn’t allowing the tuning capacitor to engage, and all the contacts were badly corroded which was killing the signal.

You can see how much gunk and oxidation had caked up onto the switch contacts – on the left, not processed; on the right, cleaned and scrubbed.

With that, the radio roared to life and picked up stations loud and clear across the dial! There were a lot of problems, but they were all able to be corrected. I peaked up the alignment using my standard signal generator, then did final inspection checks.

Finally, it was ready for the trip home! It sounded even better installed back in the cabinet.

The owners had the cabinet refinished while the radio was in the shop – it’s a perfect pairing! New pushbuttons and new rubber mounts and the radio is nearly as nice as they day it left the showroom floor.

This family heirloom is back in running shape and is going to serve faithfully for many years to come as a beautiful piece of functional furniture. Just look at it!

If you need your antique or vintage radio repaired in the Seattle area, contact Rain City Audio.

Bose Equalizers on eBay Need Service Too: A Photo Comparison

March 31, 2014 Leave a comment

You’ve had your Bose 901 Series I or Series II speakers in storage for a few years, the Active Equalizer packed away with them and now you’ve pulled them out to set up your vintage system once again. Great – keep going! Only there’s a problem: you only get buzzing or low and distorted output from one or both channels. It worked fine the last time you plugged it in!

Your first thought: go grab a working one on eBay!

And here’s the problem. One of these is a working equalizer; one is dead in need of a major overhaul. Can you tell which?

I do believe this equalizer works – and if you don’t have one, that’s a fair price for a known-good one. But even still, it’s going to need an overhaul sooner than later. It’s made of the same components, which are now more than 40 years old. If you do already have a Bose 901 Series I or Series II Active Equalizer, you can have it rebuilt and leave a complete replacement for someone who needs to replace one that’s gone missing.

Bose Active Equalizer Repair


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