Hand made Vacuum tubes

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kb0nes

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Not sure if this has ever been shared here or not. This is an excellent video of a a guy in France hand making vacuum tubes. I would imagine that a few of the AW readers may find this fascinating!

He appears to hand make all the parts, including molding the bases and machining the pins. Amazing attention to detail!



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An EXCELLENT film!Love the homemade tubes and the equipment to build them.This man is VERY talented!!!HMMM-maybe he can do a better job of rebuilding the tubes we use than the contractor we use at present.They send us GASSY tubes-not properly pumpted or gettered.---So if you try to use them-transmitter trips off and blows some components-If I try to use those tubes-cook them in the Hi Pot room for overnight on a Hi Pot tester.Like how the man plots the curves of the tubes himself-he can tailer them to whatever application he needs.And the equipment he builds to use his tubes in! Receivers and small transmitters!Our tube contractor should watch this-he may then learn how its done!!Love tubed gear too,thats why I like working on these vintage,"glow in the dark" transmitters.Love glow in the dark receivers,amps,and "G" fiddle amps,too!Remember there are some things tubes do BETTER than digital or solid state!Mainly Audio and RF amplification.
 
Indeed it is an amazing bit of work he does. He is truly a jack-of-all-trades and one of those people that just does things others would tell them that "can't be done". He did pretty much fabricate all the processing equipment. I have seen other videos he has done that showed more of the process. I'm pretty sure he MADE the vacuum pump and he has a pretty well equipped shop with old manual metal working machines.

As for vacuum tubes vs transistors I have a much more pragmatic approach. I love the old tube gear just for its vintage romance and history. I'm not fully convinced that tubes are far ahead of transistors though, except for fault tolerance and perhaps behavior when run in non-linear ways. I have quite a few vacuum tube HiFi and guitar amplifiers and a few radios too. A big part of the tube audio attraction is that of "agreeable distortion" (the same applies to Vinyl LP's). People like tubes because they sound "Rich or Warm". Sometimes I think the perceived warmth is just due to all the heat they make, perception is a strange beast!

Modern transistors have become much stronger and MOS-FET technology have raised the bar in terms of linearity and survival at high voltage. Even high power transmitters have started to change over today up to the UHF world. We now have solid state devices that are capable of linear and high efficiency operation at RF power outputs of 1Kw with only one device! Only a few years ago this would be in the vacuum tubes domain only. Just imagine how high power switching transistors have changed things like AC invertors, variable frequency drives and control of power to many devices in the home today.
 
Truly amazing. I've never took the time to understand how vacuume tubes worked, but watching this makes me wonder how they were ever invented. They were ubicuous for decades, and a great many things were accomplished with them,sad to see them relegated to history.
 
Invention of the Vacuum Tube

Really they are a pretty simple device. The invention was pretty much a fortunate "accident", much like other inventions like Nylon (Duparooh?) and Teflon.

The incandescent light was all in vogue at the time and at some point an additional element was added inside the envelope. When this was done current flow between the filament and the extra element (which would become known as the plate) was discovered. Eventually a wire "grid" was added between the filament and the plate and it was found that it could control the flow of current between the elements, turning it on and off much like a valve (ah ha!). Then it was all down to refinement. Eventually there were extra elements like a screen grid, a suppressor and beam forming plates added to make the tube do new and different things!

If you are interested in a bit of history and easy theory click the link below.

 
One of our transmitters combines both solid state and power tubes-The modulator stage is solid state-series connected modulator pulse switching modules provide the high voltage and audio signal to the plate of a VERY large,expensive water cooled power tube that is made in Germany or Switzerland.Our older transmitters have push-pull power tube modulators-These really do have better long term durablility(over 40 yrs old)and easier to service than the SS pulse step modulator.In the short wave AM transmitters we use-the modulator provides the audio modulating signal to the final stage in the transmitter-most of our transmitters use "high Level" modulation-the final RF power amp is modulated.The modulator uses the same power tubes the RF stage uses-250Kw plate disapation power tubes-triodes.Operate at 15Kv,5A per tube-fianl RF amp-26A for two like tubes-generating 250Kw output.The agency where I work has solid state MW transmitters of 600Kw,1MW of power.Thousands of transistors in these-well we can look at it another way-we can have thousands of ANTS doing the work--or two large mules.For the AM transmitters that are SS-lightening strikes can take their toll-beleive me have seen lots of this.The tubed ones kick off their OL circuits-recycle and come back on again!A tube can arc over internally a few times without damage-but a junction punctured-is shot for good.SS devices in transmitters can last for a week or years.Tubes can be more consistant in predicable life.
 
Being a former Writer/Editor

of "Vacuum Tube Valley (get it? hint: it started in Sunnyvale CA) Magazine: Celebrating the History & Technology of Vacuum Tube Technology" http://www.vacuumtube.com ...we know a little about this subject. Unfortunately, Owner/Publisher Charlie Kittleson died a few years ago at age 60, so VTV went out of publication, no one else involved had the capital to ensure continuation; an internet spin-off by the VTV Tech Editor http://wwwclarisonus.com survives. VTV would have succumbed anyway, at some point, as all small specialty print publications are now highly endangered.

In any event, French guy's craftsmanship is impeccable. However it is literally impossible for him to create tubes of the highest quality for 3 main reasons... 1.It's not likely for him to have the kind of evacuation equipment to get vacuum hardness to the best level possible. This has effect on reliability/longevity. 2. And of greater import is that some of the materials, specifically the exotic military grade layered strategic metals used as cathode materials, German ultra-pure nickel, superior reagent grade chemicals for cathode coating, etc etc just can no longer be obtained. Some of them were specially made for WE,RCA,GE, Philips, GEC, Amperex etc. and with the demise of the high volume tube industry into what is now a boutique product, manufacture of such ultra quality components could no longer be justified and are not available at any price . The problem will become even greater, and soon, with the recent demise of high volume CRT tube production for use in TVs. Use of gold plated control grids, precision spacing of grid to cathode, grid spacing and geometry, all are impossible for the boutique maker to accomplish to the degree formerly possible in the 1960s. Big Russian and Chinese factories from the Cold war era never went out of business and are now making 90% of current production tubes, mostly for the guitar market (about 95% of the market), and some of them never had this technology or materials to start with, even back in the day. Richardson and some super-specialists still make Eimac and other highly esoteric Military-transmitting-Radar tubes in the US, but that's about it, and I'm not sure even those are what they were 30 yrs ago. The new "WE" re-issue 300Bs and such are the best new tubes made for consumer but still not as good as '60s vintage. 3. He cannot have the burn-in and testing regimen needed to ensure highest quality, hugely expensive. At it's best mfr's had a significant % of clunkers that had to be weeded out. All this said, however, we're lucky that ANY new tubes are still being made, and more power to the Monsieur in France for his admirable work...Formidable! We collect/trade/restore vintage vacuum tube equipment, and it's good to know that these kind of skills and techniques are being preserved.
 
Richardson electronics primarily supplies the broadcast industries and industrial electronic heating industries-RF heating generators that use power tubes for genearating RF for induction and dielectric heating.I have dealt with Eimac for some time-originally they started as a company building tubes for "Ham" radio operators just before
WW2-they did build some tubes for the military during WW2.There is still a large market for power tubes in broadcast and industry.The military still uses tubes,too.Surprizing how much they still use.
Years and years ago-at a surplus place remember CASES of JAN 300 WE tubes-Didn't buy them at the time-had no use for them-if I had only known audiophiles love them today -would have bought the whole lot-the surplus place was selling them for only dollars for a case.
Russian tube makers also produce transmitting and industrial tubes to compete with Eimac-and good ones at that.Seventlena and Sov-Tek both produce the same lines and type # s as Eimac.Econco rebuilds transmitting tubes-sometimes their rebuilds are not good-as we experiance at our transmitter site-some of the tubes used here are available from Econco but not Eimac.The Econco power tubes we have gotten lately have not been properly pumpted-gassey-causes LOTS of problems in the transmitters they are used in-Continental Electronics Doherty rigs that are almost 65 years old!So-before installing those tubes have to "cook" them in the Hi Pot room with a Hi Pot tester-device that generates current limited HV for testing and cooking out gas in tubes and vacuum capacitors.
 
Should have picked up those WE

300 and 300Bs and 274s and... originals can go for over 1000$ apiece! And that was some time ago, not sure about current market, too rich for my blood. The crazy Asian audiophools just drive the prices higher and higher, it's better than owning stock! And as they get used up, there's even less of them to fight over.
 
I have been collecting and working with tubes for nearly 30 years. It's baffling to see what the Asian collectors will pay and for what. It's sickening to see Capehart consoles gutted for their amps and speakers.

Since I have been working in or managing movie theaters for years, I have gotten numerous calls about whether there were any old amps or speakers around. I always replied if there was they'd be at home!

I recently rescued an old amp from a drive in. It uses 805 output tubes and 866A mercury rectifiers. It's more fun to see it lit up and the rectifier tubes pulsate to the beat of the music than anything.
 
In large high power transmitter applications tubes do have an advantage in simplicity and durability. But as with everything change is inevitable...

A while back I got to tour one of the local Minneapolis TV transmitter sites. It was pretty cool to see the new analog Channel 2 transmitter that was used by the local PBS station. It ran 27Kw visual carrier in the low band VHF channel (yes I know Rex, intermediate amp power... ;) ) What was cool about it is that it was all solid state and was built from 27 combined 1000w each amplifier modules. If there was a failure they simply swap in a spare amp module and they are back to full power. They would have to lose 14 modules to have the signal drop by 3db. Yes transistors aren't as fault tolerant but this redundancy actually makes this transmitter potentially more reliable then a tube one! Of course that old analog transmitter has now been recycled since the digital conversion, but a lot of those 1000 watt amps ended up being run on the 6m Ham band!

One appliance application where of course tubes shine is for microwave ovens. At this time there is no more cost effective way to generate nearly 1000w of 2.4Ghz energy for cooking. This may not always be the case though. I know some hams that are running transistor amps in the 100-200 watt range on 2304Mhz. Inroads are being made into high frequency and high power!

There are a lot of wacky tube audio types that spend huge money on vintage NOS tubes. HiFi audio has always had its share of people on the fringe. I always like using the line "Isn't it amazing what you can imagine". A good example, a while back I ran across some Audio Quest speaker cables that have a small power supply with them to actively "charge" the insulation of the cables with 72 volts DC. An 8 foot pair of these cables costs over $10,000!!
 
Yes,breifly dealt with a Harris TV transmitter on Ch8 in Richmond ,Va.One time Harris sent them a replacement module that was green tagged--we put it in the Tx to test it-and the board brought that whole cabinet down!short in the module-was returned to Harris-they replaced it with one that worked.Their Harris Platinum transmitter was replaced with a Harris Sigma digital one-that one used Klystrode tubes in its output stage.Didn't get to see it.When the Harris Platinum SS transmitter was installed-the old tubed RCA was put out on the curb like an old dishwashwer or something-me,my freind and others salvaged parts from it.
We all forget about the magnetrons used in microwave ovens-they are still used in radar systems on Navy ships-even newly built ones.Same with the Coast Guard.A man that retired from the place where I work used to work on Navy and Coast Guard ship radars.
I used to have an Altec Lansing power amp that came from a DI theater-sort of like the one Travis had.The tubes used in that amp are used as modulators in our Continental Doherty SW transmitters-in their hayday these transmitters could delivor 500Kw of power.Now its 250Kw-use one amplifier instead of two.And the 845 mod tubes come from a supplier in China!These CEMCO transmitters use 5681,5682 tubes in the final power stages-they are the ones we have "gassy" problems with.
I also laugh about the equipment "audiophools" buy today.The cables are especially amusing.Some of these folks pay more for the patch and speaker cables than most folks spend on their whole sound systems!Not only Audiophool Hi-Fi enthusisats but muscians and their tubed guitar amps-one of these guys claims he can "tell" the difference in sound by the brand of 9V battery used in his effects "stomp" boxes!
So far for high power SW broadcasting transmitters still use tubes in the RF driver and PA stages.The modulators are the SS pulse step versions.Its something-these output tubes weigh about 300 pounds each(crane in the transmtter used to change them)Cost as much as a house-and the wooden shipping case makes for a good doghouse!They come from Germany,France,or Switzerland.
 
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