03-23-2021, 07:35 PM
I spent today making the replica electrolytic cans for the 38-10. According to the parts list one, part 12, was a two part electrolytic 4MFD and 8 MFD. The highest voltage shown in the Philco literature is 375V. The old replacements were 450V. I used two 10MFD 450V condensers for replacements. I used a 20MFD 450V condenser for part 45. Here isw the process I used for making the replica electrolytic cans...
I used 1" PVC pipe from Home Depot. They sell it in 2 foot pieces so you don't have to buy a huge long piece.
[Image: https://64.media.tumblr.com/b0ed239e38d3...a8a2fe.jpg]
I cut it into 3 pieces, two were 4 inches long, the other was less than an inch long.
[Image: https://64.media.tumblr.com/76faebd57d88...3eb233.jpg]
I sanded the outside of the 4" pieces well, all over to give the outside some tooth for the paint to stick to later. I then cleaned the pieces well with lighter fluid on a clean paper towel to remove any grease or dust from the outside.
[Image: https://64.media.tumblr.com/c21ab3b3a42d...efcdfc.jpg]
Next I took a piece of card stock, in this case cut from a Little Debbie Swiss Rolls box, and drew circles using the short piece of pipe for a guide.
[Image: https://64.media.tumblr.com/568ea90d50a1...4c702b.jpg]
I carefully cut out the circles cutting just outside the line drawn so that the diameter would be very, very close to, or a hair more than the inside of the tubes. I glued two circles together using 2 part epoxy for each top, and three pieces for each bottom. Make sure the circles are all perfectly lined up for each top and bottom. After several hours, when they were well dried and could be handled, I again used 2 part epoxy and glued the tops into the tubes.
[Image: https://64.media.tumblr.com/64dff72bc5bb...182dd8.jpg]
I drilled 3 holes into one bottom, and 2 holes into the other for the leads from the condensers. I then assembled the interior components.
[Image: https://64.media.tumblr.com/ba578a25983a...c759b2.jpg]
I ran the leads from the condensers through the holes in the bases, and glued the bases into the tubes using 2 part epoxy.
[Image: https://64.media.tumblr.com/d12873729c2a...1b2e37.jpg]
When they were well dried, I masked off the leads with newspaper, and then sprayed the tubes all over with satin finish silver Rustoleum paint.
[Image: https://64.media.tumblr.com/2ddb9cb2a239...14316f.jpg]
Using my computer and printer I made labels to go on the condensers. When the paint had dried for several hours I glued the labels onto the finished replica electrolytics using 2 part epoxy.
[Image: https://64.media.tumblr.com/859239c6907f...e8a25f.jpg]
And that is how I made replica electrolytic cans for my Philco 38-10. I hope this can be useful to others who end up having to replace the originals.
I used 1" PVC pipe from Home Depot. They sell it in 2 foot pieces so you don't have to buy a huge long piece.
[Image: https://64.media.tumblr.com/b0ed239e38d3...a8a2fe.jpg]
I cut it into 3 pieces, two were 4 inches long, the other was less than an inch long.
[Image: https://64.media.tumblr.com/76faebd57d88...3eb233.jpg]
I sanded the outside of the 4" pieces well, all over to give the outside some tooth for the paint to stick to later. I then cleaned the pieces well with lighter fluid on a clean paper towel to remove any grease or dust from the outside.
[Image: https://64.media.tumblr.com/c21ab3b3a42d...efcdfc.jpg]
Next I took a piece of card stock, in this case cut from a Little Debbie Swiss Rolls box, and drew circles using the short piece of pipe for a guide.
[Image: https://64.media.tumblr.com/568ea90d50a1...4c702b.jpg]
I carefully cut out the circles cutting just outside the line drawn so that the diameter would be very, very close to, or a hair more than the inside of the tubes. I glued two circles together using 2 part epoxy for each top, and three pieces for each bottom. Make sure the circles are all perfectly lined up for each top and bottom. After several hours, when they were well dried and could be handled, I again used 2 part epoxy and glued the tops into the tubes.
[Image: https://64.media.tumblr.com/64dff72bc5bb...182dd8.jpg]
I drilled 3 holes into one bottom, and 2 holes into the other for the leads from the condensers. I then assembled the interior components.
[Image: https://64.media.tumblr.com/ba578a25983a...c759b2.jpg]
I ran the leads from the condensers through the holes in the bases, and glued the bases into the tubes using 2 part epoxy.
[Image: https://64.media.tumblr.com/d12873729c2a...1b2e37.jpg]
When they were well dried, I masked off the leads with newspaper, and then sprayed the tubes all over with satin finish silver Rustoleum paint.
[Image: https://64.media.tumblr.com/2ddb9cb2a239...14316f.jpg]
Using my computer and printer I made labels to go on the condensers. When the paint had dried for several hours I glued the labels onto the finished replica electrolytics using 2 part epoxy.
[Image: https://64.media.tumblr.com/859239c6907f...e8a25f.jpg]
And that is how I made replica electrolytic cans for my Philco 38-10. I hope this can be useful to others who end up having to replace the originals.
