Hi Dan -- Regarding your concerns for the sensitivity of the unit, it will help if you tell me exactly what modifications you have done, as there were a number of them offered: EFB, phase inverter, driver stage feedback/HF stability design, Preamp Output/Power Amp Input jacks, buffer circuit, AF/tone amplifier revisions, and tone control bypass option. By the voltages you have provided, it would appear that at least the EFB, phase inverter, and driver stage modifications have been performed, and I think I read that you had the buffer stage all done as well. If this is true, did you also do any revisions to the AF/tone amplifier stages as well? They are required to maintain the stock sensitivity level when the power amp changes are made. Ultimately, when the complete modification is performed, a 270-280 mv signal applied to the Aux inputs will drive the unit to full power output when the tone controls are either centered, or bypassed.
Regarding the AC balance control adjustment versus balancing the output stage: May I assume that you are trying to null the voltage produced at the cathode test points when a 1 kHz signal is used to drive the output stage to about 18 watts output? If you still have the stock phase inverter installed, you will likely be able to null this out, but if you have installed mine, you likely won't be able to. That's because of a little known fact about push-pull output transformers: They ain't always perfectly balanced -- and the Fisher 400 "AX" outputs are just such an example of this fact. There are other transformers I can cite that are not perfectly balanced as well. This is not an issue with an individual transformer, but of the way a particular transformer is designed. In fact, when the phase inverter is adjusted for exactly equal outputs, and driving output tubes are exactly matched in every way, the distortion generated will be very much higher than if the drive is off-balanced to accommodate the imbalance in the output transformer. When the phase inverter is in fact adjusted for lowest distortion levels, the drive to the output tubes will not be balanced, with an offset at the output tube TPs noted. In my unit, I found that the setting for minimum distortion of the AC balance control in one channel, was within 100 ohms of the same minimum distortion setting in the other channel. As a result of this, the range of the AC balance control in my phase inverter modification intentionally targets an offset range, such that when nearly centered, the proper offset drive is provided to the output stage to in fact produce minimum distortion.
If you would like, I can measure the ratio of the cathode resistance to plate resistance in my unit, to get you very well in the ball park.
It sounds like you are rounding third for home, on a major undertaking of your receiver. I will be very interested in your opinion of the results. If I can be of any further help, don't hesitate to ask!
Dave