Quote:
Originally Posted by wa2ise
An aside: Looking at this chassis, you can see that aside from the high voltage cage, a plastic piece I see just under left of the CRT neck, and tuner, the only parts above deck are the tubes. What Zenith did was to have their assemblers (hand crafters) insert the resistors, caps and such into the cone shaped terminals. Things like IF transformer coils and trimpots had presoldered leads added to them so they could be mounted and stuffed as well. Then after all such parts were inserted, they'd take the chassis and send it thru a wave solder machine that would solder all the connections at one time. A bit like what they do for circuit boards. Then they'd add the power transformer and high voltage cage and such.
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No wonder so many sets are known for troublesome solder connections - bad or misadjusted wave solder machines. I pulled the convergence board on my '76 Electrohome console once I saw poking at the left horizontal blue pot caused the most disturbance in a crosshatch pattern. Yup, that's where the cracked solder joint is. Other connections look like problems waiting to happen so I'll redo those as well.