Radio Frankenstein

About 6 months ago I wrote the first post about my classic radio restoration project. The project is done, the radio is functional, but I somehow never got around to writing anything more about it. I'm going to try to fix that in the next series of posts.

I read a few useful guides on how to get started restoring an old radio. Bringing a radio up to life for the first time is risky-business, since the radio components can become compromised over time, and you run the real risk of burning up the radio (literally) if you're not careful.

The most useful I found was from Phil's Old Radios, recommending roughly the following:

• Spot gross defects first: leaks, stains, smells, etc.
• The electrolytic capacitors are probably dead: replace them.
• Use a variac to slowly turn the radio on.

At the high-level, my Philco was in reasonable shape: it was missing two vacuum tubes, but aside from that it wasn't leaking or showing other signs of gross physical damage.

I proceeded to test all the capacitors in the radio: there's about 10-15 of them total, so it's not that hard. The most important test for a capacitor is to verify that it's not shorted, in other words the resistance between its two leads should be infinite. Over time, electrolytic capacitors dry-up (literally), and as a result short circuit the leads, which can be catastrophic (it can burn up the power transformer, which is hard and expensive to replace).

My Philco has two kinds of capacitors:

1. Two very large electrolytic capacitors (8 muF each). These are visible on the top of the main board, and serve to smooth the DC coming out of the rectifier bridge. It is essential that these not be shorted as I explain above. Sure enough, when I measured them, one was shorted, and the other was on its way. I bough two replacement Sprague Atom's, disconnected the leads from the existing electrolytics and connected the new capacitors in place. Incidentally, the Spragues are very solid, high-quality capacitors, great to work with. Here's a sample:


2. Bakelite capacitors: these look like a little "vat" with 6-7 leads. Inside it are 2-3 capacitors, sealed in a hard, black, gunky insulator. Fortunately, none of the bakelites were bad, they all tested good on the multi-meter and, fortunately, ended up working in the end.

Serious radio enthusiasts try to "hide" the new capacitors inside the old electrolytics, in order to make the restoration even more authentic. This is a process called "re-capping", it works like this:

1. Use a Dremel to cut open the bottom of the electrolytic capacitor
2. Gut its contents, leaving an empty aluminum shell
3. Insert the new electrolytic capacitor in the old shell, solder each end to the two leads
4. Glue the bottom of the electrolytic back with epoxy glue

I got so far as step 2 above: the "gunk" inside my electrolytics was a very nasty, black, foul smelling tar-like substance that wouldn't come out no matter what. I read that some people use a hair-dryer to literally melt this stuff out of the shell, but I decided that was too much for me, so I just put the electrolytics back on the circuit board (without the bottom) and left it at that.

The next step was to replace the missing vacuum tubes. I got the complete set of schematics and repair bulletins from the excellent Philco Repair Bench. It was easy to detect that the two missing tubes were:

• Vacuum tube 80 -- the rectifier
• Vacuum tube 42 -- the power pentode

These are ancient tubes, in fact the names alone should give you an idea: the tube manufacturers simply started to count at 1 and worked their way up to around 100 or so, each number representing one type of tube. There were only a handful of tube manufacturers at the time (Philco, Tung-Sol, RCA), and they made a majority of all the tubes on the market.

I thought I'd be totally out of luck finding replacements for them. In fact, it turned out quite the opposite: there a vibrant community of old-timers who sell tubes like these for cheap. I was able to find both tubes for around $15. Not only that, but I was actually able to find them NOS = "New Old Stock", which means that the tubes were in mint condition, they had never been used! Imagine: these are tubes made 80 years ago and they still work. Here's what the rectifier looks like:


Notice how it says "Made in USA" on it. When was the last time you saw that printed on anything?

With both tubes in their sockets, now came the real test: turning on the radio. I don't have a variac, and I thought it too expensive to buy one. So instead I built a cheap home-made one: a dim-bulb tester. I first tested the radio with a large 100W bulb, and then with a smaller 45W bulb. In both cases the vacuum tubes slowly started to glow, and no weird smells or pops came out of the radio, so I decided it was safe to plug it directly into the wall.

Imagine my surprise and awe when, after 15 seconds of warm-up, the radio actually went on and started hissing! I kept a finger on the antenna lead, and was able to tune into a few AM radio stations (one was broadcasting a baseball commentary, and another had a show about aliens invading the earth).

A beautiful thing.