Disaster and Recovery
Yesterday I was working on the Earphone/Speaker Selector Switch doing the re-wiring that is part of Dave's modifications on the X-101C. In the process of moving some wires, one of the lugs of the switch broke off! I was really irritated, so I stopped. This morning after receiving an e-mail back from Dave in which I had mentioned the broken switch, he suggested I try removing some of the ceramic material around the broken off lug, enough to solder a wire back to the remaining metal.
Today, I looked at it again and thought, I have nothing to loose. I will either repair this switch or totally destroy it. After formulating a plan, I first snipped a small strip of copper from some copper grounding strap material I have left from grounding my antenna tower outside (part of a lightning protection design). I carefully folded it in half and used my Hemostats (also called Siezers in electronics) to hold it while I drilled a tiny hole in it with my Dremel tool. I prepared a short piece of green stranded hook-up wire and inserted it in the hole. I dipped the end in some rosin flux I have and carefully tinned just the end with the wire wrapped through the hole in the copper strap. I used my flush cutting wire cutters to carefully trim the slit at the other end of the folded copper strap and spread it enough to slide over the remaining metal of the switch lug. I pre-tinned the remaining part of the switch lug. I dipped the end of the folded copper strip with the green wire attached in some rosin and using some tweezers held it in place while applying heat and a small amount of solder with my pencil iron. The connection quickly mated and cooled down. A gentle tug on the end of the wire proved it is securely attached.
Using stranded wire will allow me to make a connection to the 25 ohm 5W resistor and avoid applying any added stress to the repaired lug of the switch. If Dave had not mentioned the possibility, I might not have thought of this method of repair. He is a truly ingenious person! So after some time and effort I saved buying another switch to repair this amplifier.
In the attached photograph, you will see that I also replaced both of the slide switches to the right of the Earphone/Speaker Switch. It was another case of having to use special grinding bits with diamond material to grind away the ends of the steel rivets that held the old switches.
I can use one of the slide switches as an AC On-Off switch. The contacts are rated at 5A or more so they should work fine. I wondered how the contacts could be rated so high until I looked closely at the construction of the switches. Instead of the usual raised surface seen in most slide switches, these have a raised blade as the business end of each contact. The moving contact of the switch slider consists of a U-shaped channel that slides along the entire raised business end of each contact and makes contact with both sides of the contact. These switches were from Antique Electronic Supply and were originally used by Fender Guitar Amplifiers. These are significantly better than most other slide switches I have seen.
I saved the OEM Fisher slide switches for the long slider tab that they came with. That tab is the usual Fisher reddish-brown color that makes them pretty much Fisher specific. The slide switches I am installing will all match each other and have black tabs and are slightly shorter, but still easy to operate.
I may get the rest of the speaker wiring mods finished today and take some more pictures.
Joe