[Hallicrafters] re: Rebuilding Caps

[Mike Smout]

Hi Rick

Perhaps I can be of some help to you. A month or so ago I decided to start placing the new electrolytics inside the old cans for a better sense of originality. I would take a nice new hack saw blade and sever the can just above the base. Gently saw through the can, perhaps one quarter of an inch, so not to destroy the terminal strips coming into the base. After you have severed the two pieces use a set of needle nose pliers and try to put one of the noses into the centre area of the foil and paper and the other nose a quarter inch away. Try to sink the noses in as deep as you can, half an inch or more is great. Now you can squeeze the pliers to get a good grip on the foil and paper and wrestle the contents back and fourth. You will find that it will come out in a few moments. Sometimes it will take a little more muscle, but it will come out.
Now, with the foil and paper out, you will notice that the upper part of the can has the hardened tar inside. I did all of this work outside in my garage, yes, during the winter. I use a kerosene heater to make things comfortable out there. I took the old electro can and left it on the top of the heater for a few minutes to "soften" the tar. I took a slot screwdriver and very gently stabbed the tar like substance. Try to "pry" it out in small pieces, a little at a time. Then, clean up the edges of the can after letting the tar harden once again. I find that the residue on the sides comes off much easier when hardened. Once the contents have been completely removed you can clean up the inside with sandpaper. I would then locate all of the new caps on the base, using shrink wrap to protect all leads. Drill a small hole near the base of each lead located in the base. When you have arranged all of the caps in a manner that will allow you to slide the top of the can back into place you will be ready for the final step. Use a two part, five minute epoxy. I mix up a portion that would equal a tablespoon. I coat the lower part of the caps and the top of the base, only the parts that are contained within the cap. Then I put the two parts of the cap together again, wiping off an excess epoxy that has seeped out. Align the two parts and wait one full day before you remount on the chassis. I have done approximately four caps this way and they look very professional. You too, can have the same results with very little effort. I hope this will help you. Best regards, Mike.


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