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Zeppelin Design Labs THE PERCOLATOR COMBO, Assembly Instructions Manual, Page: 36 / 74

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Zeppelin Design Labs THE PERCOLATOR COMBO Assembly Instructions Manual Download Page 36

36

TESTING THE AMP

The testing process is done with the Percolator upside down. The transformers and fins should be 
resting on the bench top. Make sure none of the weight of the amp is resting on the glass bottle of the 
tube. If it is, put some blocks of wood under the transformers to jack the amp up a little bit.

A schematic of the amplifier is printed on the template sheet that came with the kit. This schematic is for 
reference in troubleshooting, should you have problems with the amp. DC test voltages are labeled in 
red on “Figure 3: Voltage Reference” on page 39. The test procedure will consist of systematically 
measuring these voltages to ensure that your amp is within spec. Print this diagram and write your 
measurements directly on it. You don’t have to know how to read a schematic to test these voltages, but 
you do need to know how to use your digital multimeter. 
1.    WITH THE AMP UNPLUGGED, double check all your wiring. Look closely at the pictures and 

make sure the wires on your amp are correctly positioned.

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2.    WITH THE AMP UNPLUGGED from the wall, double check your solder joints. Closely examine 

every joint on the PCB and make sure they are good, solid connections.

3.    Using a 1/4” speaker cable, plug the Percolator’s output jack into an 8 ohm speaker cabinet. 

ONLY USE AN 8 OHM CABINET WITH THIS AMPLIFIER. WHENEVER YOU APPLY POWER TO 
THIS AMP, MAKE SURE IT IS FIRST PLUGGED IN TO AN 8 OHM LOAD.

4.    Make sure the Percolator’s power switch is in the off position (when the amp is upside down, the 

switch should be up).

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 Plug the IEC power cable into the IEC power receptacle on the amp. 

Make sure NOTHING is touching any part of the amplifier that shouldn’t be, and then plug the 
power cable into the wall outlet.

WARNING!

 As soon as you plug in the Percolator, there is LINE VOLTAGE across some parts 

of the exposed circuit board. Touching the board could shock, injure, or kill you! NEVER 
TOUCH ANY PART OF THE CIRCUIT BOARD WHEN THE AMP IS PLUGGED INTO THE 
WALL!

108

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Summary of Contents for THE PERCOLATOR COMBO

Page 1: ...THE PERCOLATOR ZEPPELINDESIGNLABS COM 2950 N WESTERN CHICAGO IL 60618 Assembly Instructions 2 WATT TUBE AMPLIFIER KIT ...

Page 2: ...INET 42 WHAT YOU WILL NEED 42 A WORD ON COUNTERSINKS 43 ASSEMBLING THE BOX 44 FINISHING THE BOX 54 ASSEMBLING THE CABINET 58 ASSEMBLING THE GRILL 59 COMPLETING THE HEAD 67 INSTALLING THE AMP 67 INSTALLING THE GRILL 68 USING YOUR NEW HEAD 69 CABINET TEMPLATES 70 2015 ZEPPELIN DESIGN LABS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION FROM THE AUTHOR ZEPPELIN DESIGN LABS TAKES...

Page 3: ...n making the transition to transistor development So to compete with transistors and give tubes a few more years in the market the engineers at GE developed the Compactron that could take the place of several tubes with just one bottle It was the tube equivalent to the integrated circuit They were mostly designed for use in the color TV market but some of them did find their way into radios and hi...

Page 4: ...ON indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury like cutting or burning your finger 2 WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury like shocking yourself at a wall receptacle 3 DANGER indicates an imminently hazardous situation that if not avoided will result in death or s...

Page 5: ...ents are difficult to tell apart Compare them carefully with the photos Besides verifying that nothing is missing this will acquaint you with the parts and their names If ANYTHING is missing first double check we double checked before sealing the box at our lab If it s still missing EMAIL US right away at support zeppelindesignlabs com Include your serial number given via a sticker on the chassis ...

Page 6: ... Base Plate 1 GC02 Grill Cloth Black Silver Beige 1 GF02 1 Grill Frame Top Bottom Longer 2 GF02 2 Grill Frame Side Shorter 2 HA12 Aluminum Handle 5 3 4 96mm 1 PC23 PCB Printed Circuit Board 1 PL11 Percolator Face Label 1 J3 Power Receptacle w Fuse 1 T1 Power Transformer 1 T2 Output Transformer 4W 1 V1 Vacuum Tube NOS Compactron 1 CA05 1 CA05 2 CB03 CH03 1 CH03 2 GC02 GF02 1 GF02 2 HA12 PC23 PL11 J...

Page 7: ...astic barrel 1 J2 Mono Jack w metal nut and washer Output Metal barrel 1 KN05 Knob 1 D1 Red LED 5mm 1 VR1 Potentiometer 100KA 1 R1 R6 R11 Resistor 22K Red Red Orange Gold 3 R5 R9 R10 Resistor 220K Red Red Yellow Gold 3 R3 R8 Resistor 47K Yellow Violet Orange Gold 2 R4 Resistor 820R Gray Red Brown Gold 1 R7 R14 R17 Resistor 1 5K or 1K5 Brown Green Red Gold 3 R16 Resistor 4 7K or 4K7 Yellow Violet R...

Page 8: ...R4 R7 R14 R17 R16 R2 R15 R12 R13 SK05 SK10 S1 In the Hardware bag Part Description Notes Qty CB20 Solder Lug 1 CH05 Isolation Fin 2 FT03 Foot 1 2 x1 4 4 GR02 Rubber Grommet 4 NU10 Keps Lock Nut M3 5 SC38 Philips Machine Screw Pan head M3x6 17 SC61 Philips Wood Screw Flat head 6x1 1 4 11 ...

Page 9: ...m table Work on a utility surface that you can burn drill and scratch A piece of tempered masonite or a chunk of MDF makes an excellent cover if you don t have a utility work bench CAUTION Solder fumes are not healthy for you The fumes consist of vaporized flux which can irritate your nose lungs and even your skin You MUST work in a space where the air drifts away from you as you work so fumes do ...

Page 10: ...all all of one type of component bending each of the leads as they are installed 5 Flip the board over solder side up and solder all of the components in one pass 6 Clip the leads off with small diagonal cutters right at the solder joint Let s begin 1 Standoffs Part SP11 Use 6 standoffs 6 M3 screws Part SC38 and 6 lock washers Part WA07 The plastic standoffs are installed on the solder side of the...

Page 11: ...u ll have to estimate where to bend the leads Figure 2 Component Values and Locations a Start with the 22K resistors R1 R6 R11 labeled RED RED ORANGE GOLD Compare to its picture in the BOM Find their locations on the circuit board and install and bend the leads as described above4 5 Don t solder any of them until all 17 resistors are installed just bend the leads to keep them in their place 3 4 5 ...

Page 12: ...it into their holes 6 g Continue with the 1M resistor R2 labeled BROWN BLACK GREEN GOLD h Continue with the 820 ohm or 820R resistor R4 labeled GRAY RED BROWN GOLD i Last install the 4 7K or 4K7 resistor R16 labeled YELLOW VIOLET RED GOLD j You should have a whole forest of bent leads coming out the solder side of the board 7 Now you can turn the board solder side up and solder each one to the boa...

Page 13: ...tiny ceramic caps C4 C7 11 Install solder and clip the leads b Continue with the three film caps C1 C3 C6 12 Install13 solder and clip the leads c Now for the tricky electrolytic caps Note all the electrolytic capacitors have one leg that is longer than the other 14 15 The longer leg is the positive side of the cap The positive leg the longer leg goes in the square pad PAY CLOSE ATTENTION TO THIS ...

Page 14: ...older and clip the leads18 but put one of these clipped leads aside for use in the next step WARNING The big electrolytic caps C9 C10 C11 are likely to explode if they are installed backwards which could result in personal injury Install in STRICT CONFORMANCE with these instructions f Before moving on double check the orientation of each of the electrolytic caps Make sure the stripe on each electr...

Page 15: ...make sure each lead goes in the correct hole The only indication on the circuit board of how the rectifiers should be oriented is a square pad The positive lead the longest lead22 labeled with a goes in the square hole23 The other leads should line up properly with the other holes a Install both BR1 and BR2 with this orientation Solder and clip the leads b Before moving on double check the orienta...

Page 16: ...acing away from the board The leads are too short to bend out so you just have to hold the pot while you solder at least one lead 27 It is very important to make sure all the leads are completely seated in their holes before soldering otherwise the board won t fit into the chassis properly The leads are too short to cut on this component too 9 Power switch Part S1 Carefully install the power switc...

Page 17: ...ure it feels secure 10 LED Part D1 The LED light emitting diode is a polarized component meaning that it matters which way it goes into the holes Following the standard of all the polarized components on this board the long lead goes into the square hole 30 31 If you do not install the LED in the correct orientation the on light will not work Install the LED in the holes so that the top of the LED...

Page 18: ...ll be used in the next section 12 6cm Hookup wire Part CB10 4 Strip about 1 8 3 4mm of insulation from each end of the 6cm hookup wire With your pliers bend both ends at a right angle 37 This wire goes on the solder side of the board so flip the board over and install the wire where it goes note the picture38 Solder it on the component side of the board 39 Now bend the wire along the surface of th...

Page 19: ...isted pair and straighten the ends out with your pliers 40 Strip off about 1 8 3 4mm insulation from each end of the two wires 41 On the solder side of the board install the four stripped ends in the holes marked HEATERS 42 It doesn t matter which wire goes into which of the two holes Solder each of the four ends on the component side of the board 43 44 40 41 42 43 44 39 ...

Page 20: ...y widen each of the 12 pin sockets 46 b The tube socket is installed on the solder side of the board The leads may need to be pressed in slightly for it to fit in the holes 47 Make sure all the leads are seated firmly and that the socket is pushed in as close to the board as possible 48 Double check to make sure that the top of the socket is parallel to the surface of the board c Solder the leads ...

Page 21: ...ered and making good connections If anything looks at all sketchy touch up each solder joint It s much easier to fix a problem with the board now than once it is installed in the chassis Once you are satisfied with the PCB put it aside in a safe spot until the next section when it is installed it in the chassis ...

Page 22: ... cut aside because you will use them later Cut the brown and red wires to 2 3 4 7cm 53 Strip off about 3 16 4 5mm of insulation from each of the 6 wires 54 Twist together the tiny strands of wire on each of the stripped ends Then tin the stripped part of each wire 55 56 Tinning is the process of coating or filling a wire or connector contact with solder to make it easier to attach It also helps to...

Page 23: ...he red and brown wires through the rear right grommet and the black wires through the front right grommet 57 Align the transformer mounting holes with the holes in the chassis Use two M3x6 machine screws Part SC38 and two M3 Keps lock nuts Part NU10 to mount the transformer 58 Screw down tight 59 57 58 59 54 55 56 ...

Page 24: ...the coil 60 3 Output Transformer Part T2 a Cut all of the wires coming from the output transformer to 4 10cm 61 62 Strip off about 3 16 4 5mm of insulation from each of the four wires Twist together the tiny strands of wire on each of the stripped ends and tin the stripped part of each wire 63 Don t make the tinned wire too fat b The output transformer goes on the LEFT side of the chassis Pass the...

Page 25: ...2 pcs These flank the tube socket and shield the tube from the magnetic fields from the transformers Place them as shown careful that they face the right way If you put them in backwards the tube won t fit later If the fins look like the letter L then the base of the L points towards the tube opening Use four 10x3 8 sheet metal screws Part SC68 to attach the fins 67 DO NOT OVER TIGHTEN THESE SCREW...

Page 26: ...he bottom edge of the chassis then align some of the chassis holes drop it in place and rub it down firmly over the entire surface 6 LED bezel Part SK05 Install the plastic LED bezel into its hole on the front of the chassis through the label 70 It goes in the hole to the right of the ZDL logo It should easily snap into place 7 Install the PCB Part PC23 a Flip the chassis over so the fins and tran...

Page 27: ...the front of the chassis and the tube socket is seated in its chassis hole 72 You may have to hold the board at an angle while sliding it forward to get everything to fit properly Make sure all the transformer wires are between the front and back standoffs The standoffs should line up with the screw holes on top of the chassis c Affix the PCB to the chassis with six machine screws Part SC38 placed...

Page 28: ...knob on the pot and align the white line on the knob to the position where you want the volume to be off usually between 1 00 2 00 when the amp is upside down Use a small flat screwdriver to tighten the set screw until the knob is tight 77 Now turn the knob all the way right and left through its travel The line should be between 10 00 11 00 at the maximum clockwise position The goal in setting the...

Page 29: ...transformer Place the black wires into the holes of P4 it doesn t matter which wire goes in which hole 79 Place the red wires into the holes of P280 and then place the brown wires into the holes of P3 81 In each pair it does not matter which wire goes in which hole but MAKE SURE YOU MATCH THE COLOR TO THE CORRECT NUMBER Solder all the wires in their respective holes 10 Grounding Wire Part CB10 3 S...

Page 30: ...he wire to the power receptacle lug as shown with the wire pointing to the left away from the power receptacle study the picture carefully Use the same hook and crimp technique that you used in the previous step but don t solder it yet MAKE SURE YOU ATTACH THE WIRE TO THE CORRECT POWER RECEPTACLE LUG b Now attach the other 4cm wire the end opposite the ground lug to the same power receptacle lug A...

Page 31: ...y forward and push the power receptacle through the chassis BE SURE TO INSTALL IT WITH THE CORRECT SIDE UP look at the picture 88 It may be a tight fit it could take some wrenching to get it to seat Once it is seated properly you can very gently bend the four retaining tabs of the power receptacle up if you want to ensure a tighter fit 89 87 88 89 86 ...

Page 32: ... place on the component side of the board 90 f Use your flat screwdriver to pry the fuse holder from the power receptacle 91 Pace the fuse Part F1 in the holder92 and slide it back into the power receptacle 93 12 Grounding Wire Revisited Use a M3x6 machine screw Part SC38 and one M3 Lock Nut Part NU10 to attach the grounding lug to the back of the chassis as shown 94 Screw it down tight 90 91 92 9...

Page 33: ... long 95 Strip about 3 16 4 5mm of insulation from each end of both wires 96 Tin each end don t use too much solder b Now twist the two wires together to within about 3 8 of each end 97 Solder one end of the pair to the holes labeled P5 IEC jack 98 c Solder the end of the wires to the IEC power receptacle to the two lugs shown in the picture 99 It doesn t matter which wire goes to which lug JUST M...

Page 34: ...e feedback loop wire the long wire attached to the middle of the circuit board in the FBL hole Hook the FBL wire on the tip lug of the output jack note the picture below102 if you are not sure which is the correct lug c Next attach the green wire from the output transformer to the same lug the tip lug as the FBL wire 102 Solder both wires to the lug d Next attach the black wire from the output tra...

Page 35: ...hich would mean we d have to sell you a new tube b Now flip the amp right side up again and install the tube in its socket It can only go in one way Line up the pins and then gently rock the tube 106 pressing gently but firmly down on the top until it is completely seated in the socket 107 If it has a hard time fitting into the socket make sure all the tube pins line up with the socket pins proper...

Page 36: ... UNPLUGGED double check all your wiring Look closely at the pictures and make sure the wires on your amp are correctly positioned 108 109 2 WITH THE AMP UNPLUGGED from the wall double check your solder joints Closely examine every joint on the PCB and make sure they are good solid connections 3 Using a 1 4 speaker cable plug the Percolator s output jack into an 8 ohm speaker cabinet ONLY USE AN 8 ...

Page 37: ...ll be off by the same percentage The tolerances of the tube and the rest of the components can easily vary by 5 so that could cause a bit of voltage fluctuation as well 6 Set your digital multimeter to read DC voltage In this amp all DC voltages are measured with respect to ground so the black probe of your multimeter should be held at ground potential This amp has several places at ground potenti...

Page 38: ... immediately turn on115 if it does skip to the next step If it doesn t then measure the junction of C12 and R17 TP2 in Figure 3 Voltage Reference on page 39 It should read around 6 5VDC If it does it means you either installed the LED backwards or you installed the wrong resistor in R17 Switch off the amp unplug the power cable and fix the problem If TP2 does not read around 6 5VDC by a large perc...

Page 39: ...e from the wall outlet is above or below 118 VAC or 230VAC for the international version then these voltages will be off by the same percentage If any of these voltages are significantly off beyond this line voltage percentage then it is very likely that one or more of the components are installed in the wrong place Triple check the resistors capacitors and bridge rectifiers by visually inspecting...

Page 40: ...g care not to touch the exposed circuit board Make some noise 117 Turn up the volume It should sound great 116 TIP If it turns out that you need to re solder any of the resistors don t bother removing the board from the chassis to get to the solder side just solder them on the component side of the board 117 ...

Page 41: ...20 to secure the chassis to the base plate Use a 2 Philips screw driver not a screw gun and turn just until seated DO NOT OVER TIGHTEN or you could warp the label or even worse strip out the screw hole That s it The electronics part of your amp is done Good job If you plan on installing the amp into the cabinet a simple task those notes are in the section COMPLETING THE HEAD on page 67 If you are ...

Page 42: ...ess corded or drill press Drill bits 1 16 9 64 3 16 Orbital Sander optional or sanding block Small router and 3 16 radius roundover bit or other small detail bit optional Countersink see also text below 2 Phillips Screw Driver short shaft 2 Phillips Screw Driver Awl or nail and small hammer Staple gun We prefer electric or pneumatic but manual will work fine Sharp pencil 12 Ruler Bar clamp minimum...

Page 43: ...e several ways to do this buy a 6 pilot bit 9 64 with matching fluted countersink and stop collar or an all in one 6 pilot counterbore countersink tool buy a countersink bit Use a drill bit in a drill press The first shown to the left is our favorite very accurate and easy to use The second a countersink bit shown to the right is next best If you don t do a lot of wood working you may not want to ...

Page 44: ... as shown in the diagram If you have a preference for the appearance of grain color knots etc flip the parts around this way and that until you like the way they look 121 Sometime the wood exhibits blemishes on one side from the milling process Face these toward the inside They will be completely invisible and will have no effect on the quality of the cabinet 2 With the pencil label the parts wher...

Page 45: ...from the right side 127 128 flip it over and tape it face down to the LEFT side and mark that piece as well 129 Take care when you do this that you create a PAIR of parts not two IDENTICAL parts 130 NOTE You don t have to use the handle provided with your kit You can use any handle you like but in that case check the hole spacing before you poke your marks in the cabinet top 126 127 128 129 123 12...

Page 46: ...e parts are not precisely the same width it happens they will be a tiny bit uneven on the back face that is the sides facing up That s okay don t worry about it it s the back You can fix it later when finishing the cabinet When you are satisfied with the alignment of one corner tighten the clamp to secure the parts for drilling Take your time with this step The overall neatness of your cabinet dep...

Page 47: ...late for the screws that will hold on the feet 137 Note these are the four OUTER holes nearest the corners 9 With the 9 64 bit or the combo drill countersink bit re drill the eight small holes you made in the sides plus 7 other holes as indicated on the templates one more on each side one on the top and four on the bottom NOTE These four holes on the bottom are the four 136 TIP You will get cleane...

Page 48: ...es 138 139 When you countersink practice on the four bottom holes where the depth is less critical Go easy test fit a screw and deepen the countersink a little as necessary The head should sit below the surface of the surrounding wood but only just 140 10 With the 3 16 bit drill the two holes in the cabinet top for the handle screws 141 NOTE If you use a handle other than the one provided check th...

Page 49: ...formly coats the end 145 You don t need much 13 Fit two wood screws into the appropriate two holes of the mating SIDE piece 146 Guide the tips into the little pilot holes in the top piece 147 Line up the joint accurately as you did earlier 148 132 and place the bar clamp tightly across the parts to hold them secure Use a 2 Philips screwdriver or cordless screw gun to drive the screws barely snug 1...

Page 50: ...o the remaining SIDE and maneuver them into all four little pilot holes 152 Align one joint153 and tighten the bar clamp not shown very foolish of us to attempt this without the clamp Carefully drive the two screws barely snug then align the last joint and set the last two screws barely snug 154 See also our online video for proper placement of the bar clamp 146 147 148 149 150 ...

Page 51: ... it measures the same in both directions 155 156 If necessary install the bar clamp across the longer diagonal and gently tighten it to bring the box closer to square 157 Now tighten all eight screws 158 If any glue appears on the outside of the box wipe it off with a rag dipped in warm water 155 156 157 158 151 152 153 154 ...

Page 52: ...achieve a similar look just with vigorous hand sanding We use a 3 16 roundover bit with a bearing at the bottom 162 As you route each edge be careful to orient the router so that you do not run the bearing across the screw heads 163 This will result in blemishes that could ruin your cabinet Round over all the outside edges except the four back edges DANGER Routers are dangerous tricky machines tha...

Page 53: ...ps in your joints that you cannot live with fill them with wood dough LET THE WOOD DOUGH HARDEN THOROUGHLY BEFORE SANDING That s it Congratulations Take a break and when you are ready maybe tomorrow we ll sand and finish the box 164 ...

Page 54: ...s nicely too 1 Do not sand the interior of the cabinet at all Sand the whole exterior twice using 120 and 220 grit sandpapers a If you routed a detail carefully sand out any burn marks and be careful you do not obliterate your detail with the orbital sander b Ease the square edges that is strike off the sharp square edge the mill applied to the wood Your finish ingredients cannot accumulate on a s...

Page 55: ...oat the entire cabinet inside and out 169 170 then wipe it off again with a clean rag 171 172 Rub it out thoroughly and carefully leaving no fingerprints or streaks 173 Set the cabinet down on its back propped up on a few pencils or chopsticks or triangular strips of wood Let it dry for at least 4 hours 174 170 171 172 173 174 168 169 ...

Page 56: ...erous coat to the whole cabinet inside and out 176 178 Set it back down on its back to dry thoroughly like overnight 179 5 Very lightly hand sand the exterior of the cabinet with 320 grit sandpaper 180 Ignore the interior it s done The finish is thin so be careful you do not remove the poly and damage the stained wood underneath You are trying to strike off the fuzzy grain raised in the finishing ...

Page 57: ... is dust in the air that affects the final finish 7 Apply a second coat of Wipe On Poly to the exterior Allow to dry thoroughly 183 184 8 At this point if the box is beautiful and satiny smooth you are done If it is still a little fuzzy or uneven sand lightly with 320 grit sandpaper and apply a third light coat Allow to dry thoroughly 183 184 ...

Page 58: ...e feet Part FT03 with four little sheet metal screws 6x5 8 Part SC66 into the four little 1 16 holes near the corners 185 Do not over tighten 2 Use a short screw driver to install the handle 186 using the screws that came with it 187 188 The cabinet is done 185 186 187 188 ...

Page 59: ...er and place a bar clamp across the width of the frame 191 Gently snug the clamp down on the frame just until you see glue squeezing out of all four corners 192 Wipe off the excess glue with a damp rag Allow at least 4 hours for the glue to cure 4 Remove the clamp 5 Paint the inside surfaces and one face with flat black paint or a permanent black marker 193 194 Allow to dry completely 189 190 191 ...

Page 60: ...t about doing this step call your local upholstery shop and they might be able to help you out The first part of putting on grill cloth consists of folding the 4 sides while carefully following straight lines a Set the grill cloth face down on the table The face is the side with a distinct grid pattern and broken black lines 195 Place the frame black side down neatly centered on the grill cloth 19...

Page 61: ...LINE 200 Fold over the grill cloth at the black line and crease it the entire width of the cloth 201 c Place the frame back on the cloth with the edges against the two folds Now find the line on the grill cloth one of the threads that is parallel and closest to the other long side of the frame Remove the frame and cut the grill cloth along the short folded crease to this new parallel line Once aga...

Page 62: ...e along this line 207 208 7 While holding the frame black side down onto the grill cloth turn the assembly around and look at the front The edges of the grill cloth should wrap tightly around the frame and all the lines on the cloth should be parallel or perpendicular to the frame sides Check the straightness of the lines in both directions with your speed square and make sure the back of the gril...

Page 63: ...staples around the outside Start in the middle of each side and move to the corners Alternate sides with each staple Make sure that all of the staples seat completely or the frame may not fit into the amp cabinet If some of the staples need to be pushed in further you can use your channel locks to squeeze them in Periodically check with your speed square that the lines are remaining straight in bo...

Page 64: ...e it down Leave about 1 2 from the corners without any staples 216 12 At one corner of the frame hold both corners of the grill cloth down one on top of the other Use your razor to cut a 45 degree line through both layers of cloth from the corner of the frame 217 Remove both cut corners of grill cloth 218 Use one staple to hold down the grill cloth in the corner Do this for the other 3 corners 219...

Page 65: ...his is a tricky process to apply just enough heat to tighten it up but not enough to cause the lines to warp and go crooked or even worse burn through the grill cloth We suggest you practice on some of the scraps you just cut from the frame assembly This will give you an idea of how easily the grill cloth is affected by your heat gun Start with the heat gun on the lowest setting and if that isn t ...

Page 66: ...66 over the entire area warming the whole frame evenly Be patient and take your time and you should be pleased with the results 221 222 221 222 ...

Page 67: ... the cabinet bottom 224 3 Run a sheet metal screw flat head Philips 6x1 Part SC67 through one of the countersunk holes in the cabinet bottom Use a 2 Philips driver NOT a screw gun If we all did our jobs well the screws will line up perfectly with the holes in the chassis and will dig right in Hold the amp tight to the cabinet and drive the screw in until you feel it pull the amp down tight DO NOT ...

Page 68: ...e left and right Carefully pass the bit through the countersunk hole in the cabinet top and drill a pilot hole in the frame Next drill the other two holes through the sides of the cabinet into the sides of the frame 227 3 Run a 6x1 1 4 wood screw Part SC61 through the hole in the top of the cabinet and into the top of the grill frame Repeat for the two side screws Do not over tighten the side scre...

Page 69: ...69 USING YOUR NEW HEAD For information about using your new head please read The Percolator Owner s Manual available for download on the product page at the Zeppelin Design Labs website ...

Page 70: ...T LEFT SIDE REAR FRONT BOTTOM TOP VERIFY THE TEMPLATE PRINTS ACCURATELY TO FULL SIZE CHECK BOTH SCALES WITH RULER MAKE SURE PRINTER IS SET FOR 100 ZEPPELIN DESIGN LABS LLC 2950 N WESTERN AVE CHICAGO IL 60618 WWW ZEPPELINDESIGNLABS COM REV DATE 1 27 2015 PAGE 1 of 3 PERCOLATOR 2W AMP FULL SIZE DRILLING TEMPLATES 2015 ZEPPELIN DESIGN LABS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT WRITTEN PE...

Page 71: ...TELY TO FULL SIZE CHECK BOTH SCALES WITH RULER MAKE SURE PRINTER IS SET FOR 100 LEFT RIGHT ZEPPELIN DESIGN LABS LLC 2950 N WESTERN AVE CHICAGO IL 60618 WWW ZEPPELINDESIGNLABS COM REV DATE 1 27 2015 PAGE 2 of 3 PERCOLATOR 2W AMP FULL SIZE DRILLING TEMPLATES 2015 ZEPPELIN DESIGN LABS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION FROM THE AUTHOR ...

Page 72: ...PLATE PRINTS ACCURATELY TO FULL SIZE CHECK BOTH SCALES WITH RULER MAKE SURE PRINTER IS SET FOR 100 ZEPPELIN DESIGN LABS LLC 2950 N WESTERN AVE CHICAGO IL 60618 WWW ZEPPELINDESIGNLABS COM REV DATE 1 27 2015 PAGE 3 of 3 PERCOLATOR 2W AMP FULL SIZE DRILLING TEMPLATES 2015 ZEPPELIN DESIGN LABS NO PART OF THIS DOCUMENT MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION FROM THE AUTHOR ...

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