[Power Chassis Restoration Project] - August 2007 through February 2008

After I decided to strip the chassis, and remove the rust, I got sidetracked for quite a while. I finally got around to repainting the chassis. It is not perfect, but it is a lot better than it was.

I tried several different approaches to removing the rust.. I started with Navel Jelly, Steel Wool, and then used a hose outside on a hot day to rinse it off. The idea of the hot day allowed me to dry the chassis thoroughly after its bath by letting it bake in the sun. This approach worked pretty well. I eventually resorted to a paint stripping wheel that attached to a drill. This was not a wire brush, but a wheel that looked like it was made from black corregated plastic material.

I have been in contact with several people who have obtained Stratospheres lately. It is amazing how many have come out of the woodwork.. This is still one of the most amazing radios that I think was ever made. In any case, the efforts made by these new owners inspired me to refocus on rebuilding this chassis..

My chassis did not exactly match that in the Service Manual. I have included the updated schematic, and chassis references after the photos below. I also decided to add two fuses (each side of power) under the chassis.. Plate on the chassis indicates 360 watts (3 amps..) so I will likely use a pair of 4 or 5 amp fuses. I will measure the current once the set is up and runing and adjust accordingly.

Finally, I replaced the Radio Shack terminal strips with some I got from Radio Daze.. The coloring and manufacture seems much closer to the original. The Radio Shack strips have an orange color, and they stuck out visually like a sore thumb.

February 2008 - The chassis is complete!.. I have done a bit of testing, and applied power. Full testing will have to wait for the speakers to be ready.

TIP: I wanted to replace some missing connectors on the speaker cable (where it goes to the cross-over box). I found some "butt connectors" at Radio Shack (64-3036) and the 22-18 gauge connectors worked well. Easy to solder on to the wires, and with a bit of heat shrink tubing, it makes a great terminal for the wire.

Chassis Rebuild

1) The Original condition of the chassis.


3) The cleaned up chassis with Transformers.

2) The repainted stripped chassis.

4) Cleaned Chassis with most parts mounted (12/07)

5) Finished Rebuilt Chassis Top View (2/08)

6) Finished Rebuilt Chassis Bottom View (2/08)

7) Using the Radio Shack Butt Connectors as cable connectors (1/08)
Revised Power Chassis Placement Information and Schematics

Revised Power Chassis Schematic (1/25/08)

Annotated Original Chassis Bottom Photo (1/25/08)


Updated Drawing of Chassis Top (1/25/08)