New PL400 Full WOPL Build

[Hexis22]

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.

 

[WOPL Sniffer]

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.

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.

 

[gene french]

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!!!!

 

[J!m]

I’d move that close fuse over and make a thin cover plate to hide the rework.

If recycling the chassis.

 

[Hexis22]

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.

 

[laatsch55]

YEAH!!! Stainless BABY!@!

 

[Hexis22]

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.

 

[gene french]

drill 1/4 inch hole half way between the speaker posts and the input jacks for the meter sensitivity switch if you got the white oak led board for meters...lot easier now than later...

 

[gene french]

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.

really looks nice!!!!

 

[Hexis22]

Reminder, don’t fully mount and secure the transformer before installing the screw for holding rectifier and cap hold down plate.

I forgot this screw is installed from the back side of the cap cradle.

 

[Hexis22]

The original rectifier screw protruded into the transformer:

A little work with an angle grinder to create space for the new bolt head:

All mounted up and ready to start the wiring process:

 

[laatsch55]

Lookin good....love seeing a capable hand do work like that..

 

[Hexis22]

Lookin good....love seeing a capable hand do work like that..

Thank you!

Fortunately I have many good examples to learn from and follow on this forum, combined with Joe’s great documentation.

 

[George S.]

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

 

[laatsch55]

And thank you for taking the time and trouble to document your project...

 

[gene french]

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

i had to fanagle mine...

 

[Hexis22]

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

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.

 

[Gepetto]

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

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.

 

[Hexis22]

This is what I observed in original setup, the tape did not securely hold the caps in-place and they shifted over time:

 

[girbob75]

This is what I observed in original setup, the tape did not securely hold the caps in-place and they shifted over time:

Mine looks the same but with the white caps. So close to the meter terminal!