Don'S LAST Restorations

latest additions: 19aug07  Sparton 87, SX17-03 and Pat Radio 27 to 36

Pictured below is the restored case for our RCA Western Air Patrol. (tubes:- 24A,24A,24A,227,227,45,80) Not sure of the date of manufacture. Email me if you know it. Thanks.

Gene and Phyllis Lutz passed the RCA Western Air Patrol on to me. The old gal was in tough shape with:- a baseball sized hole smashed in the upper rear left (out of picture) of the case, the finish peeling away, the rear support frame missing,  lotsa delamination and damaged feet; see pics below. 

Bought the 1920's King-Hinners chassis at a garage sale. (has 5 tubes:- 201, 201, 201, ?, ?) It needs a case, coils and meter. If you have these parts for sale please advise.

See NOTES: below for more info...


King-Hinners model 25

note missing case and meter.

King-Hinners 25

sideview. its case would be angled like this

King-Hinners 25

top view, note no coils present behind condensers

King-Hinners 25

logo

King-Hinners 25

King Quality Buffalo logo

RCA Western Air Patrol

Radio as I got it. Missing piece was found inside cabinet.

RCA Western Air Patrol

Right side was intact.

RCA Western Air Patrol

Front removed; support beams inside with front gluing jig in place.

RCA Western Air Patrol

support beams inside with rear gluing jig and temporary outer clamping beams in place

RCA Western Air Patrol

New rear "panel" glued in place. Note hole is patched with orig piece.

RCA Western Air Patrol

Sometime later the feet are restored and all is laquer finished.

Philips 905

top view with duct tape dam covering large holes

Philips 905

inside view, note epoxy resin poured in left hole before fibre glass cloth is laid into it

Philips 905

several days later after several layers of fibre glass cloth are epoxied into case to make a foundation

Philips 905

next step, grind off high spots in prep for car body filler

Group Photo

...may as well do 'em all, as do just one.

VikingEMB61-419

original shredded grill and no speaker

Viking EMB61-419

with new grill and oval speaker... now this project waits a while

Zenith ML 2608

Changer, Tuner 9L20, Amp 5L29 all connected. See next three pictures. Needed recap and tubes and modified to accept CD input into Phono input. See notes below.

Zenith 5L24 Amp

Note 5Y3 is moved away from transformer. See below, notes of 26jun06.

Zenith 9L20 Tuner

Note modifications..... DC power supply and latching relay added to rear.

Zenith 169-203

Record changer's motor shaft "steps" need repair.

BevRadio1

Note aluminum motor box, upper left, and drive shaft with pulley. Plywood bolt ons protect stuff while working underside.

BevRadio2

Station tuner shaft before installation with copper wire to keep jaws apart.

BevRadio3

Station tuner shaft installed

BevRadio4

Drive pulley and belt installed.

BevRadio5

Rogers Majestic 8R822, dial plate documentation.

BevRadio6

Rogers Majestic 8R822 everything ready for the cabinet. Note bottom plate. New grill cloth on frame on radio top.

BevRadio7

Old perished rubber grommets. New gromments. They work great! Get a 1/2" step drill for their hole.

BevRadio8

At MCMASTER .COM Load rated grommet. High damp PVC. Hole dia 0.278" Groove WD 0.070" Pt# 9311K129

BevRadio9

Same grommets used to redo 3 isolation grommets on tuner carriage.

BevRadio10

Most of components replaced in this Rogers 8R822

BevRadio11

Almost Done: red "manual" button has fiberglass retainer on back; pulley rims; electron ray tube clamp moved forward.

BevRadio12

Bev's Radio Finished. Cabinet got a touch-up, not full refinish. Still.... very pretty. Electronics A#1.

TonyRadio-01

Rogers Majestic 6R631 floor radio. Note new 6F6 tube socket. Electrolytics out for re+re.

TonyRadio-02

New electrolytics inside old cans.

TonyRadio-03

Broken pin 3 (plate on 6F6). See solder on pin clasp.... no-no!

TonyRadio-04

FInished. Replaced electros, paper caps, new tone control + ON/OFF switch etc.

Stylophone

touch pen to keyboard, it plays notes. Do you have one I could buy? Josh owns this.

Pat Radio 1

RCA 226 with very little finish left

Pat Radio 3

RCA 226 topside getting plywood protective sides

Pat Radio 4

RCA226 underside before re-capping

Pat Radio 5

lower left component board is out. upper right recapped

Pat Radio 6

ganged tuning capacitor out for new mounting grommets

Pat Radio 7

old perished grommets

Pat Radio 8

old grommets on re-assembly diagram

Pat Radio 9

stepped hole drill to widen holes for new blue grommets

Pat Radio 10

new grommets for tuning capacitor

Pat Radio 11

Freshly poured 2-part epoxy to make clamping caul for glue up of bubble in veneer.

Pat Radio 12

Epoxying in plywood force distribution bar after initial epoxy pour had set.

Pat Radio 13

Bubble #1on curved veneer, to be glued and clamped.

Pat Radio 14

Remove vertical mould wall from epoxy clamping caul.

Pat Radio 15

Drill needle holes near ink dots on tape over long bubble.

Pat Radio 16

The drill.

Pat Radio 17

The syringe.

Pat Radio 18

Injecting 70% white glue, 30% water. Next time will inject just water then heat to reactivate hide glue.

Pat Radio 19

Comparative diameters:- needle and drill bit.

Pat Radio 20

Strong back on left. Two layers of thin compression foam between caul and bubble. Places higher pressure on bubble.

Pat Radio 21

Clamp up. First the strong back, then clamp down the epoxy caul. Leave 5 days.

Pat Radio 22

Cleaning needle bore, removing obstruction with two strands of 86 guage wire used to wind IF transformers.

Pat Radio 23

Bubble #2. Injected water only. Heated bubble with hot air gun then clamped.

Pat Radio 24

Bubble #3. Inject water, heat to soften hide glue then clamp overnight.

Pat Radio 27

Veneering hide glue, hot water ladle, glue brush & chalk, veneer hammer, digital thermometer, knife, double boiler, glue storage bottle.

Pat Radio 28

Antique hotplate, restored. Iron heat collector.

Pat Radio 29

The hide glue pot. Digital thermometer in glue. Keep temp at 140 to 150 degrees F.

Pat Radio 30

Now comes selection of three pieces of veneer from the maple storage box.

Pat Radio 31

The dust proof veneer storage box.

Pat Radio 32

A book match in the making.

Pat Radio 33

The off-cut dresses up a fir block. The block will also make a great test piece for finishing.

Pat Radio 34

Tape in middle of veneer is on edge of front piece. It keeps hide glue off new veneer. Peel it off.

Pat Radio 35

Clamp up and weighing down after glue up. Not the best technique but it worked.

Pat Radio 36

Tape catches excess hide glue, keeping it off surface that will eventually be Japaned. Next comes edge routing.

Pat Radio 37

I wanted a router bit like this to fit the guide just under the veneer.

Pat Radio 38

I took 40 minutes on a high speed belt grinder to shorten the nose on this hard ceramic router bit.

Pat Radio 39

The routing is finished.

Pat Radio 40

Now we make lots of sanding blocks. Paper on two sides only.

Pat Radio 41

After step 20 in refinishing.

Pat Radio 42

Notice Japaned area bottom is not uniform.

Pat Radio 43

Nevertheless we now have the colours brought together.

Pat Radio 41

Here is the cabinet with its final top coat. Let solvents flash off for two days then re-assemble.

Hallicrafters SX-17

SX17 circa 1937. I've taken the trouble to disconnect two tuning boards to replace marked orig caps not done on prior recap.

Hallicrafters SX-17

Showing plastic caps used to replace some paper caps, likely done around 1990. In 2007 plastic caps are leaky.

Hallicrafters SX-17

Recap done on plactic caps and remaining paper caps. DEOXIDize switches. Done. It works, needs tune up.

Sparton 87

Left lower frame was missing.

Sparton 87

Making a replacement lower left base frame.

Sparton 87

A test fit.

Sparton 87

Left frame and lower rear brace glued in place.

Sparton 87

Close up of laminating. White oak on bottom of frame. Mahogany above.

NOTES:

19aug07 Doc added pics of routing Pat's radio new veneer top.

16aug07 Pat Radio finally got a new maple veneer top to replace the badly damaged original. Next comes edge trimming with a router. Then final preparation of all surfaces for the new lacquer finish. This entails making a refinishing plan based on what can be seen of the remaining old finish. Stripping the remaining old finish. Then masking is done and the whole cabinet inside is sprayed a black/brown colour. Then a methyl hydrate rub to degrease and redistribute the "under-lacquer" colour so it is even over all the surfaces. Then several spray coats of lacquer sanding sealer.  Then then solid brown "Japanning" is done on those surfaces that will not have any wood grain showing. Finally the whole thing over sprayed with several coats of specially dyed satin lacquer.

6aug07 Pat Radio got second veneer bubble re-glued. This time I just injected a bit of water under the veneer. Then heated it up with a heat gun to "steam" or re-liquefy the hide glue. Then clamped overnight.

5aug07 Pat Radio is ready for another bubble in the veneer to be glued using custom designed epoxy clamping block.  Used up left over epoxy glue (from Pat's Radio clamp block making project) on all the glue up needed on the Sparton 87. Otherwise would have had to throw out the expensive epoxy after it set in the freezer. (It only keeps 4 days in freezer before it sets.... even at freezer temperature)

3aug07 Finished SX17 recap. Jim at Ham club walked me through using the tuning systems. We'll likely put a scope and signal generator on this old buggy in the fall. Jim take note of shielded wire running from add-on toggle switch under SW4. Shielding runs to RCA jack on rear. What for.... we'll see next fiddle.

28jul07 Added PatRadio11,12,13 and Hallicrafters SX-17's first two pictures.

29oct06 Drove through snow storm to Horse Lake with Bev's Rogers Majestic 8R822. She was thrilled. Finest radio in the Cariboo. State of the art 1938.

22sep06 Added Pat Radio pictures to this page.

15sep06 Rebuilt RCA 226 radio chassis energized and it works. Ordered new grill cloth, misc parts to complete resto.

1sep06 Started restoring Pat's 1935 RCA 226 floor radio. This will be a complete resto, cabinet and chassis.

28aug06 Finished repairing the Stylophone for Josh. If you have one to sell contact me please.

26aug06 Finished Tony's 6R631 resto. He came and picked it up today.

21aug06 Started Tony's 1938 Rogers Majestic 6R631 floor radio. Found broken tube socket. Re+re the electrolytic capacitor cans with new electrolytic cap inside old cans to keep authentic look and make future servicing easier.

20aug06  Nearly finished Bev's radio. Added fiberglass rims to the two pulleys. This raised the pulley rims so the flat drive belt can not ride up the rim and jump off the pulley.

12aug06  Almost finished Bev Macauley's 1938 Rogers Majestic 8R822 floor radio.

2aug06  New phono motor and idler wheel arrived from West Tech Services, for Ruth's Zenith Record Player. Installed 'em. They work great Gib. Thanks! Ruth is happy.

26jun06    Added pictures of Ruth's Zenith ML2608 AM/FM Radio Record Player components out of the "box". Did the usual recap and tube replacement as required. Vertical chassis mount meant the 5Y3 was under the power transformer. The 5Y3's heat went straight up to the transformer and added to its heat. The result a "hot" smelling radio after a while. Solution: move the 5Y3 to one side so its heat plume is away from transformer.  Then modified  the phono circuitry slightly to allow the input of stereo signals from her new CD and cassette taper player. Originally, when the PHONO selector was pressed the amp looked at the phono inputs instead of the radio AND the B-plus would only energize when you turned on the phono motor.  In adding the ability to select the CD player as an input source a DPDT toggle switch was added to select the L+R audio feed from either the CD or Record Player to the amp. If you want the Record player you press the PHONO button as per normal.  If you want CD player, select its audio input to amp by using the DPDT toggle switch. Then you press PHONO and a nearby push button that energizes a DPDT latching relay.  One pole serves to latch the relay ON. The other pole, when ON, feeds the neutral connection to the B-plus power transformer so you don't have to turn on the record player motor to energize the amplifier's B-plus whilst playing CD's or tapes. The relay's second pole, when OFF, routes the neutral from the record player motor  switch to the B-plus power supply transformer to allow the amplifier to work as per normal when you press the PHONO button and turn on the record player motor.  Ppphheww! Several evenings' work there. Gib Epling's West Tech Services in West Virginia is looking after repairs to the motor and phono idler wheel.

sept05    I will add pictures of a 1938 Rogers Majestic floor radio that I am restoring for Bev Macauley who lives at Horse Lake, near 100 Mile House in British Columbia. Until she moved there she was our next door neighbour here in Chilliwack.

Edited June 30, 2008 By: Gord Routley - Don's HostMaster, Guru & Friend!