Monday, September 3, 2012

Hallicrafters SX-96 Component Replacement

Most of the parts to be replaced are easy to get to. I've replaced most of the caps - saving a potentially annoying section for last.




Part of S2 - Selectivity Switch
Click to enlarge

This section seemed like the most annoying, so I saved it for last. There are six bees hiding in and around this multilayered switch. The good news is that it isn't quite as annoying as I'd initially thought it would be. Note the circled area - three bees and a wire are attached to a single point. The primary concern for something like this is the relatively fragile attachment point - these switches may be difficult to find, and repair is not something I care to think about.


S2 Schematic
Click to enlarge 

Since the connection is delicate, a minimum amount of heat is applied to melt the solder. First, I drew a diagram of the mess, in addition to the photo. Next, I cut the wire lead of the bee close to the body of the part - leaving sufficient wire so that it could be grabbed with needle-nose pliers. Carefully heating the joint with the 25 watt soldering iron, I used a spring powered vacuum device to remove a blob of molten solder. I had to heat it twice, since woven component leads make it hard to get enough solder out of the joint to remove the leads. Once the joint was partially clear, it was heated a second time. Wires are bent like hooks in these joints. I used the needle-nose pliers to grasp one of the wires, and moved it around within the connection when the solder was molten. I removed the heat, and continued to move the wire quickly so that the small amount of remaining solder would not tack it to the point again.


Partially cleared tie point...
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Note the appearance of the remaining solder - it appears dull and rough. This is the result of moving the wires as the solder cooled, the desired effect so that the part wouldn't re-tack itself, allowing easy removal.


Cleared pad
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The connection is now clear for the new parts.
Next - The switch with new parts.