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Right you are...the joys of working with materials available (in a reasonable time frame)! Plus, the Teflon machines so much better than that damn Nylon.

Well...Eric is showing the bolt head/nut bearing directly on the bushing and the washer is between the bushing and the chassis/transformer case Electrically this works but mechanically it would be better to have the bushing sandwiched between the chassis/transformer and a washer so the loads...

OK, I guess I went the extra mile and made sure everything was isolated. Here you can see the white bushing under the washer on the outside cap. Which is the bushing on the right side of the bolts below: As you can see all of the bushings extend into the core laminations to make sure...

Hang on a sec...do you put the transformer cradle directly in contact with the amp chassis? You don't say anything about putting a bushing between them so you are connecting them electrically. I checked my set-up and I don't get anything between chassis-bolt-transformer-chassis so I think I...

You mean like this?

OK, problem solved...just a quick trip back to the lathe and machine a shoulder in the shoulder...(it was 5mm thick to start with) and then top it off with a Teflon washer... But I'm still curious about why basically everything has to be isolated from each other...

OK, now I'm confused o_O...so in addition to electrically isolating the transformer/transformer housing from the chassis and the bolts, I need to also isolate the bolts from the chassis? My plan was to electrically isolate the transformer/transformer housing from the chassis using the Teflon...

My understanding of the stack-up puts the Teflon washers between the transformer and the chassis so the thicker shoulders shouldn't make any difference (other than making the bolts appear shorter) or do I understand wrong?

Well, checked around town and nobody from auto parts stores to industrial supply houses had the shoulder bushings for the transformer isolation. I found some on Amazon and Ebay but the best I could do pricewise was some dude in France and a pack of 10 would cost about €12...delivered sometime...

Mine seem to make contact a little sooner and if you tried you might get bit but nevertheless I'm reworking the lines to power up the tip as you recommended. I like your little loop in the connecting wire, not sure mine is going to look as neat but we'll see how they turn out.

OK, so that does put the 100V right there by the opening and ready to get your finger if you should stick it in there... But if you connect to the tip, when you are inserting the fuse you also run the risk of getting a little bite... So basically you are screwed if you do, screwed if you...

I have been doing a lot of thinking about how to wire up the fuse holders...tie the barrels together like I have done or tie the top posts together...got examples of both Both by the same builder...I'm so confused... But does it really matter which "side" of the fuse holder you have hot...

I'll go back and touch both of them up but they were good and hot, solder just melted like crazy when it touched the fitting (even though I had the iron mostly on the wire) but just in case...

Made a little progress today, mostly mechanical work, test fitting things to work on wire routing...Still need to get/make the bushings for the transformer bolts, clean the boards, prep the heat sinks and then I can start with "real" final assembly. Well, winter is here, might as well...

Got the first snow today so I got a few bits and bobs soldered in. The alcohol I was using for cleaning had some friggin' surfactant or something in it and left a film on the board...got some 99,9% isopropyl on the way, should be here next week (the joys of living in the middle of nowhere)...

Bingo! The quasi threw me...

Joe, I still haven't found this BOM that you refer to...and is there some sort of narrative that goes along with the assembly slide show?

I wish I could say that I left those unsoldered on purpose to see if anybody was really looking and you won the prize for attention to detail but damn, good catch! (you get the prize for attention to detail anyway!!!) You are right, I put all of the test points in and only soldered "most" of...