New PL400 Full WOPL Build

Working on the original housing and installing an IEC socket.

It fits, but not a clean install that I'm proud of... Getting closer to ordering Joe's replacement housing.

IMG_5398-X2.jpg


IMG_5402-X2.jpg


IMG_5404-X2.jpg


IMG_5409-X2.jpg
 
Hexis22 said:
Working on the original housing and installing an IEC socket.

It fits, but not a clean install that I'm proud of... Getting closer to ordering Joe's replacement housing.

IMG_5398-X2.jpg


IMG_5402-X2.jpg


IMG_5404-X2.jpg


IMG_5409-X2.jpg
Click to expand...



Joes new chassis' have the extra room and for as much time as it takes to do that mod, a new chassis is a no brainer. Plus, stripping the old chassis takes time and the new chassis is ready for the small parts you need to populate it like the new fuse holders speaker jacks and RCA's.
 
just did one...was very tight...but its installed and working just great!!!!
looks nice from here!!!

working these original chassis is quite a chore....i have one of joes and one original ....
joes was much easier...more room...
original works...and is cheaper...
use whatever fits your situation!!!!
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I’d move that close fuse over and make a thin cover plate to hide the rework.

If recycling the chassis.
 
Finally getting back to the build after many weeks of travel for business.

Collecting all required stepped washers and bolts to electrically isolate the transformer mounting. Not sure this is an absolute must, but figured as long as I have it apart and the transformer is securely mounted it shouldn't hurt.

I went with Stainless 10-32 X 4" bolts and nylock nuts. The nylon stepped washers were found at local hardware store and fit the transformer perfectly. I will likely need to trim the bolts to length after initial mounting.

XFMR%20Bolts-XL.jpg
 
Now that all the white thermal grease is cleaned up, housing assembly has commenced. Cleaning all that thermal grease has been the worst part of the build to date, that shit gets everywhere... Lots of paper towels, Simple Green, and a toothbrush worked well.

Still need to make a support for the transformer now that the fins are mounted.

IMG_E5507-X2.jpg

IMG_5502-X2.jpg

IMG_5501-X2.jpg
 
Hexis22 said:
Now that all the white thermal grease is cleaned up, housing assembly has commenced. Cleaning all that thermal grease has been the worst part of the build to date, that shit gets everywhere... Lots of paper towels, Simple Green, and a toothbrush worked well.

Still need to make a support for the transformer now that the fins are mounted.

IMG_E5507-X2.jpg

IMG_5502-X2.jpg

IMG_5501-X2.jpg
Click to expand...
really looks nice!!!!
 
If you clean the double sided tape off the cradle you'll gain a little needed clearance between the storage cap buss bar and Dixson meters stud.
This is a potential issue with using the original chassis that Joe has rectified with his deeper replacement chassis.
More than one member has fired up his WOPL with a intermittent short there, and it's a critical point to check once the face plate is mounted.
Here's a old post about it.
https://forums.phxaudiotape.com/threads/wopl-400-and-dixon-meters.9513/#post-264047
 
George S. said:
If you clean the double sided tape off the cradle you'll gain a little needed clearance between the storage cap buss bar and Dixson meters stud.
This is a potential issue with using the original chassis that Joe has rectified with his deeper replacement chassis.
More than one member has fired up his WOPL with a intermittent short there, and it's a critical point to check once the face plate is mounted.
Here's a old post about it.
https://forums.phxaudiotape.com/threads/wopl-400-and-dixon-meters.9513/#post-264047
Click to expand...
i had to fanagle mine...
 
George S. said:
If you clean the double sided tape off the cradle you'll gain a little needed clearance between the storage cap buss bar and Dixson meters stud.
This is a potential issue with using the original chassis that Joe has rectified with his deeper replacement chassis.
More than one member has fired up his WOPL with a intermittent short there, and it's a critical point to check once the face plate is mounted.
Here's a old post about it.
https://forums.phxaudiotape.com/threads/wopl-400-and-dixon-meters.9513/#post-264047
Click to expand...
I’ll keep an eye out for that clearance, it was very close on the original setup as well.

I left the double sided tape in place to cushion the caps against the cradle, but will reevaluate if additional clearance is required.
 
George S. said:
If you clean the double sided tape off the cradle you'll gain a little needed clearance between the storage cap buss bar and Dixson meters stud.
This is a potential issue with using the original chassis that Joe has rectified with his deeper replacement chassis.
More than one member has fired up his WOPL with a intermittent short there, and it's a critical point to check once the face plate is mounted.
Here's a old post about it.
https://forums.phxaudiotape.com/threads/wopl-400-and-dixon-meters.9513/#post-264047
Click to expand...
The hold down plate has a cutout to avoid that occasional problem. Align the divot in the plate to the stud location and you will have plenty of clearance.
 
This is what I observed in original setup, the tape did not securely hold the caps in-place and they shifted over time:

IMG_5196-X2.jpg
 
Hexis22 said:
This is what I observed in original setup, the tape did not securely hold the caps in-place and they shifted over time:
Click to expand...
Mine looks the same but with the white caps. So close to the meter terminal!
 
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