Wow, Crane was fast. Ok, so here are the voltages that we got from the amp today (it has a marstran PT on the 490v taps):
pin1 pin2 pin3 pin4 pin5 pin6 pin7 pin8 pin9
v1 246 0 1.8 241 0
v2 204 0 1.28 362 205 206
v3 274 28 47 277* 30 47
v4 494 492 -64 491
v5 493 492 -64 496
v6 495 495 -64 495
v7 496 495 -64 493
I wrote down all the voltages that we actually measured.
* this was the only voltage deviating noticeably from George's voltage chart with his 500v mains tranny. After we swaped around tubes, we got 264v on v3's pin 6, which means that also this voltage is pretty much spot on in our understanding. Or do you see any issues with any of the voltages guys?
Crane installed the 1ohm resistors on 2 output sockets and measured bias. Unsurprisingly it was on the cold side. He brought it up to 30mA if i got that correctly. The amp sounded noticeably warmer and it got also more breakup on the same setting, but it didn't do anything to the issues:
Amp still has very low headroom - amp starts to break up with a les paul copy (paf style pickups, gibson classics, if i'm not mistaken) on the hi input on bright channel at vol. 1.5, gets crunchy at 3. Hotter bias gave actually even a bit more break-up.
The amp seems to work annoyingly well (for a troubleshooting situation) - no unexpected noises, crackles, it is also not unexpectedly low in volume, it has little background noise - not more what you'd expect from a good tube amp and it seems to take volumes of over 8 very well without any technical problems.
I tested ALL resistors, all mustards, micas and pots before it was put together. Crane measured and formed the electrolytics with Larry's method. All rifas went fast under 5v and the nos 32uF@450v Erie got under 4.5v after a while and then Crane stopped forming it (Larry wrote that anything under 5v is good). He even measured the ESR on the old and some of the new filter caps. All was fine - the old one had almost the same ESR.
The issues seem to be also very consistent - there are no noticeable changes.
I rechecked all trannie color codes - compared them with Marstrans diagrams and the amp - the OT taps look correct to me.
Crane tried to spot some mistakes, but all was done correctly. He might be able to tell you more on what else he did and checked.
We even tried the amp with 2 tubes only, to see if some from the quad might be causing the issues, but it was pretty much the same thing (with just a tiny bit shriller and slimmer overall tone).
So the situation is this - amp seems to work like it should, but has low headroom (it is probably not more silent than it should be, it just breaks up much too quickly for this model) and from 3 on vol. it starts to add a bit of ghosting, at a bit higher settings the ghosting becomes VERY appearant, pretty much all over the fretboard, not just past the 12th fret - it sounds really like a harmonizer effect on the higher settings - 7 and upwards.
The distortion, especially on the bass strings is very farty, undefined, flabby, what ever attribute you want to throw at it and the distortion has some degree of fizziness that i don't hear in other people's clips, but that might be a recording-reality-issue. Or that farty bass problem.
Sorry for the long message, but i tried to squeeze in what we've done so far.
Any advice would be greatly appreciated, guys! You guys here have seen almost every imaginable issue with these amps and i hope you can give us a few directions for further troubleshooting.