AUDIO OUTPUT TRANSFORMER PROJECT, SAVE ME! - VACUUM TUBE RADIO REPAIR - PART 2 Emerson 641B [4K]

or "How I Learned to Stop Worrying and Love Rebuilding Transformers"
(with rusty junk, improper tools and loads of time...)

In Part 1 (see playlist below), we did the troubleshooting on this radio.
   • Emerson 641B  

It turned out that it had a blown audio output transformer. So, that's why they gave up! You know, because they cannot be fixed...right? Certainly not without special tools and training and a large amount of skill, right?

In this Part 2, let's see what we can do with bits of junk and rusty old tools and a boatload of time... can we save it? Without buying proper tools and careful precision? Let's just give it a try and run-through and see what is involved - will it even work??

BTW, I spent 10-12 hours (!) on this (not including editing out many hours of video).

See the checklist which appears, when status changes, for tracking what is discovered that needs addressing in Red, followed by Green when resolved.

Someday I may electrically restore this radio, if so, the playlist will link the restoration video with these resurrection videos. Turn on notifications to see if that video ever gets done.

This is not instruction, it is for entertainment for people like me who enjoy watching projects and the experiences gained. If you attempt to do some of the things in this video you are at your own risk. I am using special tech-bench safety equipment not detailed here so don't take for granted you can just plug these old items in safely without them being checked and repaired correctly. Check out the link below to Mr Carlson's Lab video below.

Vintage equipment used along the way:
Emerson Model 641B vacuum tube radio ca 1952
Heathkit Model IG-72 vacuum tube Audio Generator ca 1962

Acknowledgments and References:
[note: am in no way representing how these folks have shown doing this - I don't even think they would approve. I just took some bits of information and a lot of inspiration, and just gave it a shot with minimal tools and concern for precision, just to give it a try.]

Excellent, very clear and helpful discussion and demonstration of transformer measurement and characterization by Uncle Doug:
   • Output Transformers: A Discussion of ...  
‪@UncleDoug‬

Excellent videos on re-winding transformers by RestoreOldRadios, search his channel for many examples:
   / restoreoldradios  
‪@RestoreOldRadios‬

Excellent video showing winding a transformer core by Delatsch:
   • Practical Transformer Winding Tutoria...  
‪@Delatsch‬

Special thanks to Doug at DERB for the shout-out here:
   • Something Different - Testing the BDE...  
‪@DERB_Seymour_Indiana‬

Awesome discussion of bench safety including variacs and isolation transformers by Mr Carlson's Lab (highly recommended):
   • Tech Tips Tuesday, Isolation Transfor...  
‪@MrCarlsonsLab‬

Modification method for a commercial Tripp Lite isolation transformer for tech-bench use by Todd Harrison, his channel is called ToddFun:
   • ToddFun.com: Isolation Transformer - ...  
‪@ToddFun‬

Thanks to shango066 for championing the approach of "fix it first", before mass re-capping. Had the person who attempted this repair used that approach, they would have had a much better result. See shango066 for many examples of that approach.
‪@shango066‬

Camera: Canon G7X Mark III
Mic: Rode Micro
Video Editing Software: Power Director
Video Editor: just me