Zeppelin THE PERCOLATOR Assembly Instructions Manual Download Page 63

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47. Remove the dust with a vacuum or compressed air and inspect all the seams. If there are any

gaps you cannot live with, fill them with wood dough. Pack it in tight, leave some extra on the
surface, and then leave it alone for at least four hours to harden thoroughly.

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That’s it! Congratulations.

Take a break, or go work on the baffle, or take a bike ride, and when you are ready we’ll sand and
finish the box.

Summary of Contents for THE PERCOLATOR

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

Page 2: ...24 TESTING THE AMP 38 ASSEMBLING THE CHASSIS 43 BUILDING THE CABINET 44 A WORD ON COUNTERSINKS 45 ASSEMBLING THE BOX 45 FINISHING THE BOX 64 ASSEMBLING THE CABINET 68 MAKING THE SPEAKER CABLE 69 BUILD...

Page 3: ...ompetitor The GE corporation which was one of if not the most prolific tube developers in the world at the time was well invested in their miniature tube line and wasn t too interested in making the t...

Page 4: ...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 ser...

Page 5: ...Orbital Sander optional or sanding block 17 Small router and 3 16 radius roundover bit or other small detail bit optional 18 Countersink see also text below 19 Staple gun We prefer electric or pneuma...

Page 6: ...at we goofed and shorted your kit we will get replacement parts in the mail to you as soon as possible If you lose or damage anything we will be glad to sell you replacements The unusual or custom com...

Page 7: ...Handle 1 LS08 Loudspeaker 8 8 ohm 1 PC23 PCB Printed Circuit Board 1 PL11 Percolator Face Label 1 J3 Power Receptacle 1 T1 Power Transformer 120V Primary 1 T2 Output Transformer 4W 1 TM02 Paper Templ...

Page 8: ...o 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...

Page 9: ...er Grommet 4 NU10 Keps Lock Nut M3 5 SC38 Philips Machine Screw Pan head M3x6 17 SC63 Philips Sheet Metal Screw Pan head 8x1 2 Assembling the chassis 4 SC68 Philips Sheet Metal Screw Pan head 10x3 8 A...

Page 10: ...32 Baffle 4 SC13 Philips Machine Screw Pan head 8 32x3 4 Speaker 4 SC61 Philips Wood Screw Flat head 6x1 1 4 Cabinet 30 SC66 Philips Sheet Metal Screw Pan head 6x5 8 Attaching the feet 4 WA06 Flat Was...

Page 11: ...as the Zeppelin Design Labs logo on it The other side of the board is called the solder side which as the name implies is the side on which the legs of the components are soldered to the board Proper...

Page 12: ...how to decode these stripes but we will identify each resistor for you by simply naming the stripe colors and giving you the value and the part number Figure 2 Component Values and Locations on the ne...

Page 13: ...just bend the leads to keep them in their place b Continue with the 220K resistors R5 R9 R10 labeled RED RED YELLOW GOLD c Continue with the 1 5K or 1K5 resistors R7 R14 R17 labeled BROWN GREEN RED G...

Page 14: ...ip each lead with your flush cutters at the solder joint 9 l Before installing any more components on the circuit board double check the resistance values of each of the installed resistors Set your d...

Page 15: ...nger 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 WHEN YOU ARE INSTALLING THESE CAPS It is ver...

Page 16: ...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 ea...

Page 17: ...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 orientatio...

Page 18: ...o 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 28 29 9 Pow...

Page 19: ...orrect orientation the on light will not work Install the LED in the holes so that the top of the LED stands about 7 8 23mm off the surface of the board 32 Solder the LED on the component side of the...

Page 20: ...ur 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...

Page 21: ...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...

Page 22: ...Very gently use your awl to slightly 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 t...

Page 23: ...make sure everything is well soldered 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 insta...

Page 24: ...st 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...

Page 25: ...e 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 scre...

Page 26: ...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 o...

Page 27: ...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...

Page 28: ...y set it in place 69 GET IT RIGHT THE FIRST TIME YOU WILL NOT BE ABLE TO RE POSITION THIS LABEL Line up the bottom edge of the label with the bottom edge of the chassis then align some of the chassis...

Page 29: ...The input jack side of the board should be closest to you Slide the PCB forward as the input jack pot and switch fit through the holes on the front of the chassis and the tube socket is seated in its...

Page 30: ...nob 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 th...

Page 31: ...ich 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...

Page 32: ...ower 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 RECEPTAC...

Page 33: ...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 On...

Page 34: ...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 recep...

Page 35: ...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...

Page 36: ...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...

Page 37: ...ich 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 p...

Page 38: ...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 108 109...

Page 39: ...if the input voltage from the wall outlet is off by a certain percentage then all of the rest of the voltages in the amp will be off by the same percentage The tolerances of the tube and the rest of t...

Page 40: ...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 41 It should read around 6 5VDC If it does it m...

Page 41: ...ge from the wall outlet is above or below 118 VAC 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...

Page 42: ...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...

Page 43: ...d chassis 118 It is a snug fit 2 Use four sheet metal screws pan head Philips 8x1 2 Part SC63 two in front119 two in back120 to secure the chassis to the base plate Use a 2 Philips screw driver not a...

Page 44: ...ow we make the pre finished Percolator Combo here in our lab There are as many carpentry and finishing techniques as there are carpenters and finishers If you prefer to do something differently go for...

Page 45: ...then countersink with the bit carefully and gradually adjusting the depth of plunge until the full diameter of the bit just barely cuts into the wood The screw should then pull the head down into the...

Page 46: ...e wood size PERFECTLY it happens there s a note on some of the templates showing which edge of the wood to line it up with If there is no note the alignment is not super critical just center the templ...

Page 47: ...of each Rear Cleat 130 129 130 6 Front Cleats Part CA06 6 Fold the longer template along its length and wrap it around one of the longer cleats 131 Tape down the template 132 Mark the holes on two sid...

Page 48: ...four cleats with the long Front Cleats toward the middle and the shorter Rear Cleats toward the left and right Compare the TOP and IN labels to the photo 138 Each long cleat should have three marks a...

Page 49: ...143 Note the cleat is cut a little short so check it at both ends and center it on the cabinet side This is much easier than it sounds Finally check the offset from the front edge once more it s bett...

Page 50: ...for the two short Rear Cleats is similar but note you use the Port piece to space them up from the bottom and in from the back edge 146 Be SURE to space these cleats in a little far from the back edg...

Page 51: ...are countersinking in a separate step go back now and countersink all the holes in the Cleats using your chosen method NOTE Be sure to countersink the last pair of holes on the long Cleats on the side...

Page 52: ...and drive the screws home 155 If the clutch spins out early increase it ONE STEP AT A TIME just until the cleat goes down firm to the cabinet side DO NOT OVERTIGHTEN as the screw will either spin out...

Page 53: ...er and we roll right across that front edge as well so we skip this step 157 22 Now stand up the Top Sides and Bottom on their FRONT edges on your clean smooth flat work surface Dry fit them together...

Page 54: ...th this step The overall neatness of your cabinet depends on getting this step right 161 25 Fit your drill with the 5 64 bit sticking out about 1 1 8 At the corner you lined up drill two holes at the...

Page 55: ...his time use the 9 64 bit to drill the 4 chassis mounting screw holes in the front of the cabinet With a 5 64 bit drill the 4 badge mounting holes in the front as well 165 28 Change to a 3 16 bit and...

Page 56: ...d 168 168 31 Fit two wood screws into the appropriate two holes of the mating SIDE piece 169 Guide the tips into the little pilot holes in the TOP piece Set a clamp across the box as shown barely snug...

Page 57: ...the clutch at its LOWEST SETTING press in hard and drive the two screws barely snug You will tighten these later 173 173 34 Now attach the BOTTOM to the same SIDE holding the joint secure with a clamp...

Page 58: ...the remaining SIDE and maneuver them into all four little pilot holes Align clamp and screw the joints barely snug one at a time 178 179 177 178 179 36 Dry fit into place the Front and the lower Port...

Page 59: ...ssary use the other clamp to hold the joints tight as you drive the screws home Do not over tighten You will only sink them too deep into the side or spin them out or worst break off the head Proceed...

Page 60: ...th clamps to squeeze the Front tight against the cabinet Top 189 From the rear run a wood screw in through the cleat and spin it a few times with a Philips screw driver to mark the Front 190 Repeat fo...

Page 61: ...94 192 193 194 44 Re drill the six little holes in the Ports with the 9 64 bit and countersink them 195 195 Glue the LOWER PORT ONLY into place Apply glue to the cabinet bottom and to the cleats just...

Page 62: ...me There s only room for a small chamfer or roundover If you don t want to use a router you can achieve a similar look simply with a lot of hand sanding We use a 3 16 roundover bit with a bearing at t...

Page 63: ...s you cannot live with fill them with wood dough Pack it in tight leave some extra on the surface and then leave it alone for at least four hours to harden thoroughly 203 203 That s it Congratulations...

Page 64: ...stains nicely too We illustrate some of the following procedures on a 1x8 speaker cabinet The process is identical on the Combo cabinet 1 Do not sand the interior of the cabinet at all Sand the whole...

Page 65: ...here will strongly influence how uniform your stain turns out later 2 Remove the dust blast it with compressed air draw it off with a shop vac or wipe with a clean rag 208 208 3 With a clean rag appl...

Page 66: ...roduct that is thin enough to soak straight into the wood but thick enough to provide a decent finish without running or dripping Pour a little product into a disposable metal cup like the bottom inch...

Page 67: ...reful you do not remove the poly and damage the stained wood underneath You are trying to strike off the fuzzy grain raised by the finishing process so far This sanding should produce a fine white pow...

Page 68: ...f it is still a little fuzzy or uneven sand very lightly with 320 grit sandpaper and apply a third light coat Allow to dry thoroughly That s it Look at that gorgeous thing you made You re some kind of...

Page 69: ...25 226 The cabinet is done 227 227 MAKING THE SPEAKER CABLE 1 Take the 6 zip wire Part CB11 and split the ends about 13mm Now use your flush or diagonal cutters and cut off about 3 16 4 5 mm from ONE...

Page 70: ...ce CAUTION Solder residue usually contains lead which is poisonous if you ingest it Do not breathe the fumes do not eat the supplies wash your hands after you handle solder and sweep and wipe up your...

Page 71: ...solder terminals exposed 233 233 5 Tin the two contact points on the jack as shown 234 235 234 235 6 Solder the slightly shorter ribbed wire to the negative lug as shown 236 Now solder the other wire...

Page 72: ...the contacts 242 242 9 Slide the jack barrel along the wire and over the jack Screw it on tight 243 Take the jack out of the clamp or vise and this baby is done 243b 243 243b 10 Test the continuity of...

Page 73: ...ey are powering so it is very important that this cable is functioning properly If there s ever a problem with your cable you ll know how to fix it Disassemble the jack and look for bad solder joints...

Page 74: ...5 Use the drill and the 9 64 bit to drill the four holes in the corners of the board If you have a drill press use it Otherwise take care to hold the drill as straight up as you can Hold the baffle fi...

Page 75: ...work on the cabinet while you are waiting 9 Now it is time to put on the grill cloth Attaching grill cloth in a way that looks nice is not an easy task There are two goals to keep in mind in working...

Page 76: ...ove the baffle board and fold the cloth over on that silver line and crease it the entire length of the grill cloth The bent edge should be at a 90 degree angle 255 256 253 254 255 256 b Place the baf...

Page 77: ...hat is parallel and closest to the the other side of the baffle opposite the first fold Remove the baffle board and cut the grill cloth along the previously folded crease to this new parallel line 261...

Page 78: ...d mounting holes Alternatively if you own a Percolator 2 Watt Tube Amplifier by Zeppelin Design Labs orient the cloth to match the pattern on the amp grill While holding the baffle board black side an...

Page 79: ...f each side and move to the corners 268 Alternate sides with each staple Put the staples in at a 45 degree angle so that all the staples aren t lined up in the middle of the edge 269 If any staples ar...

Page 80: ...th corners of the grill cloth down one of top of the other Use your razor to cut a 45 degree line through both layers of cloth from the corner of the baffle board Remove both corners of cloth that wer...

Page 81: ...fected by your heat gun Start with the heat gun on the lowest setting and if that isn t hot enough you can move up from there Also start with the heat gun at least 12 away from the grill cloth move cl...

Page 82: ...eaker cable to the speaker terminals 284 Be careful to solder the ribbed wire to the negative terminal the one marked with a 285 Solder the wire with writing on it to the positive terminal marked with...

Page 83: ...83 That s it The baffle board is done Set it aside until the cabinet is complete 284 285 286...

Page 84: ...her Part WA10 around the shaft of a 6x1 1 4 sheet metal screw Part SC69 Run the screw through one of the holes in the cabinet face Use a 2 Philips driver NOT a screw gun If we all did our jobs well th...

Page 85: ...baffle board 291 SM161 291 2 Place the cabinet on its back and drop the completed baffle into the front Orient the baffle so that the cable is facing toward the amp 292 293 292 293 3 Poke a 6x1 1 4 w...

Page 86: ...into place careful to place it in the same orientation as previously 6 Place a 8 Finish Washer Part WA10 over the end of a 6x1 1 4 wood screw Part SC61 and drive it through one of the holes and into...

Page 87: ...er Port in place careful to put it in the same orientation as when you drilled the holes look for your mark under that dark finish Tap it tightly into place against the cleats 299 Run the last four wo...

Page 88: ...he Percolator 1x8 Combo Owner s Manual online from the same place you found this manual Go to www zeppelindesinglabs com Navigate to the product page for the Combo either DIY Kit or Assembled Ready to...

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