Well, after some experimentation and practice, I'm pleased to announce that I've perfected an excellent method of re-stuffing the old TVL and FP style cans with new electrolytics in a manner which permits re-using the original terminal lugs and hides the "rough edges" of the repair underneath the chassis.

I've also (get ready for this, as it's a HUGE step) successfully reactivated the existing insides of a multi-section twist-lock capacitor! Since I have a commercial interest in not disclosing too much detail just yet and since I've only been able to do this ONCE successfully so far, I'll leave the particulars out for now. The downside is that forming the reactivated sections took several hours, but I have a feeling that I know what part of the process can be improved to shorten the forming time. I'll post more after I've tried the "tweaks" I'm considering.

Results with the first successful trial have been ESR less than one ohm, leakage current of 1/5*sqrt(C*V) microamperes, capacitances well within factory tolerance.

I would like to hear more, if it is not all a big secret.

I'll post more info after I've had significantly more than just one successful trial run. I also need to do some "hostile environment" testing to make sure the process provides high reliability and ruggedness. Once I'm sure the first success was more than just a fluke and that the units will consistently survive in real-world usage, then I'll definitely share the results of this research.

For now, the unit is occupying the "C222A/B" positions in a third-party clone of the RCA 630 chassis that I'm still not quite finished recapping. Incidentally, that set will be equipped with "hidden" fuses for horizontal sweep, AC line, and B+ as has become "standard equipment" whenever I recap a set and will be subjected to even more extensive testing than my usual three-day times 8-hour burn-in.