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Electronics Repair (sci.electronics.repair) Discussion of repairing electronic equipment. Topics include requests for assistance, where to obtain servicing information and parts, techniques for diagnosis and repair, and annecdotes about success, failures and problems. |
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Radio alignment tools
Hello all!
I am working on a 2 meter (146 MHz) radio kit, and I am faced with the need to adjust various coils and transformers in it. The directions point out which ones can be adjusted with a metal tool, and which ones really need a non-metallic tool. My first non- metallic tool was a cheap plastic flat-blade screwdriver meant for adjusting trimpots. It started out OK but the tip quickly got chewed up and it started slipping. So, I get out the regular (metal) screwdriver set, and managed to crack one of the cores with my enthusiasm... I have a new coil on the way and now I am looking at real, official alignment tools. Basically, I see pure plastic tools of varying materials, tools that are a metal core covered in plastic, and some fancy ceramic ones. I'm pretty sure I don't want the ones with a metal core. The plastic ones are inexpensive. The ceramic ones sound like they would be more robust, but they also might be more brittle. My immediate need is for a small flat-blade tip about 1.5 to 2 mm wide, and a larger flat-blade tip about 4 to 6 mm wide. It seems like you can get a better deal on sets of tools, which is fine, as long as it has the ones I need. In the future I might be using them on other two-way radios, for sure from 450 MHz down to 50 MHz, and then possibly on some radios below 30 MHz. I don't anticipate using them much on AM or FM broadcast sets, or television sets. Are there any particular brands or features that are recommended, or unfavored? Any sets that are particularly good for this application? (I like the idea of the ceramic ones, but if they break a lot they may not be worth the cost.) Thanks for your help! Matt Roberds |
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Alignment tools are not always cheap. The good ones will not break or wear
out very easily. They are machine, and or moulded to fit exactly to the coil core. A proper alignment tool will have a minimal effect on the coil's performance, due to being inserted with the tool. The links below should give you something to go on to find an alignment tool kit. http://www.oselectronics.com/ose_p62.htm http://www.radiodaze.com/tooltool.htm http://www.hmcelectronics.com/cgi-bi...duct/3480-0015 -- Jerry G. ====== wrote in message news:7VcWd.215$Fy.156@okepread04... Hello all! I am working on a 2 meter (146 MHz) radio kit, and I am faced with the need to adjust various coils and transformers in it. The directions point out which ones can be adjusted with a metal tool, and which ones really need a non-metallic tool. My first non- metallic tool was a cheap plastic flat-blade screwdriver meant for adjusting trimpots. It started out OK but the tip quickly got chewed up and it started slipping. So, I get out the regular (metal) screwdriver set, and managed to crack one of the cores with my enthusiasm... I have a new coil on the way and now I am looking at real, official alignment tools. Basically, I see pure plastic tools of varying materials, tools that are a metal core covered in plastic, and some fancy ceramic ones. I'm pretty sure I don't want the ones with a metal core. The plastic ones are inexpensive. The ceramic ones sound like they would be more robust, but they also might be more brittle. My immediate need is for a small flat-blade tip about 1.5 to 2 mm wide, and a larger flat-blade tip about 4 to 6 mm wide. It seems like you can get a better deal on sets of tools, which is fine, as long as it has the ones I need. In the future I might be using them on other two-way radios, for sure from 450 MHz down to 50 MHz, and then possibly on some radios below 30 MHz. I don't anticipate using them much on AM or FM broadcast sets, or television sets. Are there any particular brands or features that are recommended, or unfavored? Any sets that are particularly good for this application? (I like the idea of the ceramic ones, but if they break a lot they may not be worth the cost.) Thanks for your help! Matt Roberds |
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wrote in message
news:7VcWd.215$Fy.156@okepread04... [snip] In the future I might be using them on other two-way radios, for sure from 450 MHz down to 50 MHz, and then possibly on some radios below 30 MHz. I don't anticipate using them much on AM or FM broadcast sets, or television sets. Regardless, in most newer TV's, AM and FM radios, you'll find no place to use any of those tools. Those old coil days are gone forever! -- An economist is an expert who will know tomorrow why the things he predicted yesterday didn't happen today. Laurence J. Peter |
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"N Cook" wrote in message ... Most tool/ ferrite damage is done trying to overcome the varnishes or whatever introduced after factory alignment. I just use a dab of hot-melt glue when done, theory being it should look like hot-melt to anyone else coming across my fiddlings I used nail polish. The color makes it easy to spot and it holds well but breaks easily. It doesn't run down in the threads either. N |
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Travis Jordan wrote:
Fiberglass works best for most iron hex cores; plastic is an acceptable substitute. Any 2-way radio shop in your town will have hundreds of these tools and perhaps will give you one if you ask nicely. Or for $10 buy a set of your own. http://www.oselectronics.com/ose_p62.htm Forgot to mention - you'll want to be sure to get a small steel blade tip tool for those pesky little trimmer capacitors. A GC Waldom # 8605 will do fine. |
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On the RadioDaze link, click on the picture of the Universal Color TV
Alignment Tool Kit and look at the white tool. Then click on the picture of the CB Alignment Tool Kit, 8 Piece, and look at the first red tool on the left. Both of these are plastic tools, with a tiny metal blade fitted into the end. The piece of metal is small enough that it doesn't appreciably alter the tuning, and tough enough that it will not mush when you turn the core. I've had these tools for years, and they seem to work well. Bill ===================== Jerry G. wrote: Alignment tools are not always cheap. The good ones will not break or wear out very easily. They are machine, and or moulded to fit exactly to the coil core. A proper alignment tool will have a minimal effect on the coil's performance, due to being inserted with the tool. The links below should give you something to go on to find an alignment tool kit. http://www.oselectronics.com/ose_p62.htm http://www.radiodaze.com/tooltool.htm http://www.hmcelectronics.com/cgi-bi...duct/3480-0015 |
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NSM wrote:
I used nail polish. The color makes it easy to spot and it holds well but breaks easily. It doesn't run down in the threads either. N I used a drop of canning wax. If you need to realign it later its easy to melt with the tip of a soldering iron, and lubricates the threads while its still soft. -- ? Michael A. Terrell Central Florida |
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"Do Litlle Jr." wrote:
Regardless, in most newer TV's, AM and FM radios, you'll find no place to use any of those tools. Those old coil days are gone forever! Not in transmitters and commercial radios. -- ? Michael A. Terrell Central Florida |
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Take a look at
http://www.gcwaldom.com/catalog/css/catalog_179.html wrote: Hello all! I am working on a 2 meter (146 MHz) radio kit, and I am faced with the need to adjust various coils and transformers in it. The directions point out which ones can be adjusted with a metal tool, and which ones really need a non-metallic tool. My first non- metallic tool was a cheap plastic flat-blade screwdriver meant for adjusting trimpots. It started out OK but the tip quickly got chewed up and it started slipping. So, I get out the regular (metal) screwdriver set, and managed to crack one of the cores with my enthusiasm... I have a new coil on the way and now I am looking at real, official alignment tools. Basically, I see pure plastic tools of varying materials, tools that are a metal core covered in plastic, and some fancy ceramic ones. I'm pretty sure I don't want the ones with a metal core. The plastic ones are inexpensive. The ceramic ones sound like they would be more robust, but they also might be more brittle. My immediate need is for a small flat-blade tip about 1.5 to 2 mm wide, and a larger flat-blade tip about 4 to 6 mm wide. It seems like you can get a better deal on sets of tools, which is fine, as long as it has the ones I need. In the future I might be using them on other two-way radios, for sure from 450 MHz down to 50 MHz, and then possibly on some radios below 30 MHz. I don't anticipate using them much on AM or FM broadcast sets, or television sets. Are there any particular brands or features that are recommended, or unfavored? Any sets that are particularly good for this application? (I like the idea of the ceramic ones, but if they break a lot they may not be worth the cost.) Thanks for your help! Matt Roberds |
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"Michael A. Terrell" wrote in message ... "Do Litlle Jr." wrote: Regardless, in most newer TV's, AM and FM radios, you'll find no place to use any of those tools. Those old coil days are gone forever! Not in transmitters and commercial radios. True, however, if one compares an old Collins auto-mechanical transmitter / receiver (the one with brass gears) from end WWII era, with the latest designs than you have to admit that alignment / tuning has also changed dramatically. Now with all crystal controlled PLL frequency synthesizes, pre-tuned ceramic/crystal devices and cavity resonators, the need for realignment / tuning has really been minimized, specially in the IF sections. |
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"Do Litlle Jr." wrote:
"Michael A. Terrell" wrote in message Not in transmitters and commercial radios. True, however, if one compares an old Collins auto-mechanical transmitter / receiver (the one with brass gears) from end WWII era, with the latest designs than you have to admit that alignment / tuning has also changed dramatically. Now with all crystal controlled PLL frequency synthesizes, pre-tuned ceramic/crystal devices and cavity resonators, the need for realignment / tuning has really been minimized, specially in the IF sections. A lot of old equipment is still in daily use, in some fields. I have worked on transmitters up to 130 KW Visual and 65 KW aural. You don't replace these every year or two. I worked on the production line for an $80,000 (US) telemetry receiver (RCB2000)and there were still a lot of adjustments to be made even though it had a dual DSP front end, massive FIR filtering, digital signal combining and 12 microprocessors. I had a set of ceramic alignment tools that cost a couple hundred dollars issued by the test department. The replacement tips were around $45 and would shatter if dropped to the floor the wrong way. -- ? Michael A. Terrell Central Florida |
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Michael A. Terrell wrote:
I worked on the production line for an $80,000 (US) telemetry receiver (RCB2000)and there were still a lot of adjustments to be made even though it had a dual DSP front end, massive FIR filtering, digital signal combining and 12 microprocessors. I had a set of ceramic alignment tools that cost a couple hundred dollars issued by the test department. The replacement tips were around $45 and would shatter if dropped to the floor the wrong way. Classic government contracting stuff, eh? Is Microdyne still around? |
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"Travis Jordan" wrote in message ... Michael A. Terrell wrote: I worked on the production line for an $80,000 (US) telemetry receiver (RCB2000)and there were still a lot of adjustments to be made even though it had a dual DSP front end, massive FIR filtering, digital signal combining and 12 microprocessors. I had a set of ceramic alignment tools that cost a couple hundred dollars issued by the test department. The replacement tips were around $45 and would shatter if dropped to the floor the wrong way. Classic government contracting stuff, eh? Is Microdyne still around? NASA sites still use some Microdyne receivers and a lot of Harris Multifunction receivers (MFR) for telemetry. |
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Derelict wrote:
"Travis Jordan" wrote in message ... Michael A. Terrell wrote: I worked on the production line for an $80,000 (US) telemetry receiver (RCB2000)and there were still a lot of adjustments to be made even though it had a dual DSP front end, massive FIR filtering, digital signal combining and 12 microprocessors. I had a set of ceramic alignment tools that cost a couple hundred dollars issued by the test department. The replacement tips were around $45 and would shatter if dropped to the floor the wrong way. Classic government contracting stuff, eh? Is Microdyne still around? NASA sites still use some Microdyne receivers and a lot of Harris Multifunction receivers (MFR) for telemetry. Don't you have that backwards? The government was buying Microdyne equipment to replace aging Harris systems. We built a turnkey system for NOAA at Wallops Island to replace a Harris system they couldn't keep up and running. We were allowed two weeks after delivery to get it to meet specs. The engineers arrived a day early, uncrated the racks that night and wired them together. The next morning the facility's manager took one look and told our team they could go home, it was perfect. We also built a turnkey system for the Italian space program, including a portable system in a large trailer that was to be towed behind a two ton truck, followed bu a diesel generator. We also built a one of a kind modified 700 series KU band receiver for the International Space Station. I was involved in all three projects, as well as preparing the RCB-2000 for the production floor. Most Microdyne products were built with the tech in mind because we had to do so much custom work on every unit. There were pages of options, and we were always adding new items that customers requested. -- ? Michael A. Terrell Central Florida |
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"Michael A. Terrell" wrote in message ... The L3-Com prototype was so poorly designed we kept the mockup on display in the Manufacturing Engineering office for everyone to see how not to do things. It was flimsy, poorly laid out and would have been a nightmare on the production floor. A lot of the software out there is not designed any better. I worked for three years on very large database systems. Occasionally, for amusement, I would tell my co-workers that as I walked in the door on my first day I was concerned that I would be unable to measure up to the knowledge and skill of the other people there. Inevitably they would break out in hysterical laughter, tears streaming down their faces. N "To retain respect for sausages and laws, one must not watch them in the making.". Otto von Bismarck |
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NSM wrote:
"Michael A. Terrell" wrote in message ... The L3-Com prototype was so poorly designed we kept the mockup on display in the Manufacturing Engineering office for everyone to see how not to do things. It was flimsy, poorly laid out and would have been a nightmare on the production floor. A lot of the software out there is not designed any better. I worked for three years on very large database systems. Occasionally, for amusement, I would tell my co-workers that as I walked in the door on my first day I was concerned that I would be unable to measure up to the knowledge and skill of the other people there. Inevitably they would break out in hysterical laughter, tears streaming down their faces. N My first day on the job I was assigned a "Trainer" to bring me up to speed and warned that I only had six weeks to get up to at least 70% of the work produced by the existing techs. By the end of the first day I was repairing modules the trainer thought were scrap. The start of the next week I got my test stamp five weeks early, and the following Monday a "Committee" of angry techs arrived at my bench and threatened me. They ordered me to reduce my output, because I was making everyone else look bad. I smiled and gave them three options. They could work harder, they could work faster, or they could get out of my face because I wasn't working up to my ability yet and they weren't going to stop me. I made some enemies, and a lot of friends. I offered to teach them better techniques and logical troubleshooting. Some took the offer and got better, while others just grumbled and insisted they were the best techs because they had been there for 15 years or more. -- ? Michael A. Terrell Central Florida |
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"Michael A. Terrell" wrote in message ... My first day on the job I was assigned a "Trainer" to bring me up to speed and warned that I only had six weeks to get up to at least 70% of the work produced by the existing techs. By the end of the first day I was repairing modules the trainer thought were scrap. The start of the next week I got my test stamp five weeks early, and the following Monday a "Committee" of angry techs arrived at my bench and threatened me. They ordered me to reduce my output, because I was making everyone else look bad. I smiled and gave them three options. They could work harder, they could work faster, or they could get out of my face because I wasn't working up to my ability yet and they weren't going to stop me. I made some enemies, and a lot of friends. I offered to teach them better techniques and logical troubleshooting. Some took the offer and got better, while others just grumbled and insisted they were the best techs because they had been there for 15 years or more. What is it the Marines say? "Lead or follow but get out of my way"? I once got a new job and was sent to head office for a week's training as a HVAC estimator. On Wednesday they told me I could leave now, since in two days I'd learned everything I could be taught and I hadn't been too subtle about it. N |
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NSM wrote:
What is it the Marines say? "Lead or follow but get out of my way"? I once got a new job and was sent to head office for a week's training as a HVAC estimator. On Wednesday they told me I could leave now, since in two days I'd learned everything I could be taught and I hadn't been too subtle about it. N I wrote software to calculate the cost of retrofitting older homes with better insulation and storm windows in 1986. It also created a B.O.M. and a sheet of calculations on how long it would take to pay back the cost to upgrade. There was already one commercial product on the market. It took two or three hours to enter all the data into the forms, and reloading three different paper forms into the printer. It leased for $1,000 a month. I did it on a Commodore 128 with three printers, and you could enter the data and do the calculations in under 15 minutes. Total cost was a couple hundred dollars. It was fun to see people jump when three different dot matrix printers started spitting out paper on the shelves behind them. -- ? Michael A. Terrell Central Florida |
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Michael A. Terrell wrote:
The prices are high because the production numbers are low. On the And because there is a tremendous amount of overhead in the bidding and contract management process. And then you have the 'added value' from DCAA, DCAS, DCMA, DCMC, and of course the ACO. Thank you, taxpayers. |
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Travis Jordan wrote:
Michael A. Terrell wrote: The prices are high because the production numbers are low. On the And because there is a tremendous amount of overhead in the bidding and contract management process. And then you have the 'added value' from DCAA, DCAS, DCMA, DCMC, and of course the ACO. Thank you, taxpayers. We were so niche that we usually got the frantic phone call asking, "Is there any way you can make model # XX do this?" Some systems took a lot of time to bid, but they were usually sure they would get it before spending much time preparing a bid. -- ? Michael A. Terrell Central Florida |
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Michael A. Terrell wrote:
We were so niche that we usually got the frantic phone call asking, "Is there any way you can make model # XX do this?" Some systems took a lot of time to bid, but they were usually sure they would get it before spending much time preparing a bid. I remember a few times where a contract went to a lower bidder, and then later the contracting agency would come back to us with their hat in their hands and ask if we'd be interested in submitting a new bid for a slightly modified system. That was a clear sign that the low bidder couldn't deliver, and you can be sure the folks involved in the rebid knew that there wasn't going to be any competition.. |
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