Celebrate The Golden Age Of Radio Today.

Gutting old capacitors and stuffing them with new capacitors

I do this process for people who want to hide the new usually neon yellow or orange capacitors inside the old capacitor casings. IT IS NOT REQUIRED but if you want the inside the chasssis to look untouched then stuffing the old casings is great, but time consuming. You need a lathe, some common clear plastic hose, drill bits, old capacitors, and tons of patients. This method is great for PAPER CAPACITORS and won't work with oil filled capacitor. Paper caps are usually brown or with Zenith they are the red ones. Don't attempt the black ones with the solder balls on either end. They are filled with oil which could be highly poisoness. Just get rid of those.
1. Use the clear hose to protect the old capacitor casing. You can split it with a razor to allow it to adjust to the old capacitor diameter size.
2. Put the hose incased old capacitor in the spinning chuck of the lathe and tighten down gently.
3. Start out with  a small drill bit in the stationary chuck. Drill completely through the old capacitor slowly. Move up in size with the drill bit till the internal roll of paper either gets bored out or just gets pushed out the other side.  It takes alittle practice so don't try on your best looking one first. You should have an empty tube when finished that will allow the new capacitor to easly slide in place.


4. Once gutted get a hot glue gun. Being quick about it gently glue new capacitor in old capacitor casing. Be carefull to NOT melt the new capacitor with the glue. It can happen and destroy your new capacitor. Once the glue has cooled holding the new capacitor in place you then can seal up the ends with more hot glue. This takes a little practice. The glue is like hot taffy and it cools quickly. So so I apply around the end of the casing first then lead to the new capacitor lead while slowly turning and balancing the old casing to get the glue to flow and solidify in a concave manner. Like I said it takes some practice but it works well. Must be quick because the glue does cool and dry fast. You can always add more if needed and it does not need to be perfect. Just make a cap for the capacitor out of glue, not a biggie.

5. Once cooled and ghost white you can paint the ends to blend in with the rest of the old casing. I suggest a matt brown or off black. Any can of paint will do with a cheap brush. Once dried you won't be able to tell old from new if you do it well.

6. Finished product above. All new capacitors hidden in old casings. As you can see you don't have to be perfect with the glue, paint, or even using the original casings for that radio. It looks original no matter how they came out. Only someone who matches the part numbers printed on the side casings to the part numbers on a schematic will be able to tell. I bet no one does that and if so....who really cares what they think! Thats nuts, find something better to do with your time! Ok, good luck.
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