Repairing a amplifier damaged wooden side panel.

[Audioflyer]

First time I ever attempted a repair like this!
This is how I repaired the damaged side panel from my £10 bargain Sansui AU101 amplifier.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend01.jpg

I've cut away the old veneer using a craft knife.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend02.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend03.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend04.jpg

Then I've cut some new veneer pieces.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend05.jpg

I needed to repair the damage to the inner core so I used some softwood to make the infill.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend06.jpg

Trimmed the inner core to shape in line with the existing veneer.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend07.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend08.jpg

Attach the new veneer pieces with a hot clothes iron.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend09.jpg

After the glue had dried I then shaped the newly repaired panel with a craft knife.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend10.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend11.jpg

Finished off with some sanding to blend in the new and old veneers.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend12.jpg

There was a few dents in the existing veneer that I've removed, by using a damp tea towel and a hot iron, this work by drawing the compressed dent out.

More to come filling and finishing.

Sharif.

[dave2010]

How long has it taken you so far?

Would be good to see it when it's all finished, but it seems to be getting there.

Well done, and good luck.

[The Barbarian]

But the original are vinyl wood grain effect arnt they?

[Audioflyer]

But the original are vinyl wood grain effect arnt they?

It is real American Black Walnut Veneer.

[Audioflyer]

How long has it taken you so far?

Would be good to see it when it's all finished, but it seems to be getting there.

Well done, and good luck.

As it was something new to try I estimated it has taken between four half to six hours.

Sharif.

[Audioflyer]

Part 2 of my Sansui AU101 wooden side panel repair.

I've applied a few coats of Ronseal American Walnut Stain and left it to dry over night.

After the stain had dried there was a visible line were the new and old veneers joined.

The solution was to use some artist acrylic paints from the wife’s paint box.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend14.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend16.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend13.jpg

I then cut the excessive paint off and lightly sanded over the join.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend17.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend15.jpg

Further colour matching was done with furniture colour markers.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend20.jpg

Furniture colour wax was used to fill in the wood grain to match the original veneer.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend18.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend19.jpg

To finish off nice coat of bees wax was applied.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend21.jpg

Side panel final assembled to the freshly resprayed top cover.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend22.jpg

And finally the finished amplifier with two missing knobs.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/SansuiAmp06.jpg

Sharif

[The Barbarian]

It is real American Black Walnut Veneer.

The one i has was not real wood veneer!

[Audio Al]

Great job

you would not notice the repair unless it was pointed out

[walpurgis]

That's come out rather well. If you want to fill any small holes, try brown wax 'heel ball' for shoe repairs. It works well and can be polished up after.

[337alant]

Excellent job, nice Amplifier too :eyebrows:;)

Alan

[RobbieGong]

Excellent job, nice Amplifier too :eyebrows:;)

Alan

Ditto ! :thumbsup:

[Techno Commander]

Thats a tidy job. :)

[seoirse2002]

Part 2 of my Sansui AU101 wooden side panel repair.

I've applied a few coats of Ronseal American Walnut Stain and left it to dry over night.

After the stain had dried there was a visible line were the new and old veneers joined.

The solution was to use some artist acrylic paints from the wife’s paint box.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend14.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend16.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend13.jpg

I then cut the excessive paint off and lightly sanded over the join.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend17.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend15.jpg

Further colour matching was done with furniture colour markers.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend20.jpg

Furniture colour wax was used to fill in the wood grain to match the original veneer.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend18.jpg

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend19.jpg

To finish off nice coat of bees wax was applied.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend21.jpg

Side panel final assembled to the freshly resprayed top cover.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/Sansuiwoodend22.jpg

And finally the finished amplifier with two missing knobs.

http://i681.photobucket.com/albums/vv175/audioflyer/Sansui%20AU101%20Referb/SansuiAmp06.jpg

Sharif

OH NO!!:eyebrows::eyebrows: I just saw a broken one at the boot sale for a tenner! thought about it,and left it:rolleyes: If I had known I could have got it for you just for the knobs

[Audioflyer]

Thanks all for the comments I'm very pleased with the repair and I'm surprised by how good it sounds after a good service.
I had to change all the caps as most of them had dried out with many of them passing a small amount of DC.

Repairing the wooden side panel has give me the confidence to tackle and repair the cabinet damage on a pair of JBL L40.


OH NO!!:eyebrows::eyebrows: I just saw a broken one at the boot sale for a tenner! thought about it,and left it:rolleyes: If I had known I could have got it for you just for the knobs

That's a shame! I've been looking but haven't found one yet.

Sharif.

[Mothman]

That is great job Sharif you wouldn't know you'd done a repair.

I had a similar issue with the side panels on my AU-505 but not having your skills I cheated and removed the original veneer with a heat gun and then filled the damage and applied iron on veneer to match the rest of the oak furniture in the room :)

http://i32.photobucket.com/albums/d45/okmothman/DSCF2542_zps8804f6ea.jpg (http://s32.photobucket.com/user/okmothman/media/DSCF2542_zps8804f6ea.jpg.html)

Final result was OK but unfotunately ampey no workey :(

[Audioflyer]

That is great job Sharif you wouldn't know you'd done a repair.

I had a similar issue with the side panels on my AU-505 but not having your skills I cheated and removed the original veneer with a heat gun and then filled the damage and applied iron on veneer to match the rest of the oak furniture in the room :)

http://i32.photobucket.com/albums/d45/okmothman/DSCF2542_zps8804f6ea.jpg (http://s32.photobucket.com/user/okmothman/media/DSCF2542_zps8804f6ea.jpg.html)

Final result was OK but unfotunately ampey no workey :(

That looks good I hadn't thought about matching it to the furniture as ours is oak as well.

Sorry to hear it not working but if you power it up with your speakers attached does it do any thing?

Sharif.

[Mothman]

Hi Sharif, my AU-505 suffers from crackling in the left channel. In an effort to cure it I had the amp re-capped a couple of years ago with Elna Silmic II's throughout except for the small 1uf caps which were replaced with Panasonics. Unfortunately the re-cap didn't cure the problem and the crackling returns when the amp has warmed up. I then tried lots of goes at cleaning the pots & switches with Servisol but again with no joy and so the amp has been mothballed since.

Anway bit the bullet yesterday and took the amp to the local Hi-Fi doctor for a diagnosis and possible further surgery. Lets hope the patient isn't terminal.

[The Barbarian]

tbh if this had been me id had made a whole new pair of sides.. 2 mins on the table saw.

[Audioflyer]

Hi Sharif, my AU-505 suffers from crackling in the left channel. In an effort to cure it I had the amp re-capped a couple of years ago with Elna Silmic II's throughout except for the small 1uf caps which were replaced with Panasonics. Unfortunately the re-cap didn't cure the problem and the crackling returns when the amp has warmed up. I then tried lots of goes at cleaning the pots & switches with Servisol but again with no joy and so the amp has been mothballed since.

Anway bit the bullet yesterday and took the amp to the local Hi-Fi doctor for a diagnosis and possible further surgery. Lets hope the patient isn't terminal.

Ah the switches I dismantled the ones on my AU101 as I was having the same problems inside the contacts were black.
I cleaned the up with a glass fibre tip pen and washed them with Servisol, when I reassembled them I re-lube the contacts with some switch/relay oil.

Well I hope you manage to get it sorted with the electronics tech.

Sharif.

[awkwardbydesign]

tbh if this had been me id had made a whole new pair of sides.. 2 mins on the table saw.
Only works if you have a table saw! Fortunately, I do.
http://i1134.photobucket.com/albums/m604/awkwardbydesign/26052013830_zps76872803.jpg

[6L6]

Fantastic looking repair, thanks for posting!