• WARNING: Tube/Valve amplifiers use potentially LETHAL HIGH VOLTAGES.
    Building, troubleshooting and testing of these amplifiers should only be
    performed by someone who is thoroughly familiar with
    the safety precautions around high voltages.

SUPER budget DIY tube amp - need help

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Being as passionate as I am about what I'm working with, I REALLY don't want the vacuum tube industry to die. From my observations, it's been holding on by threads since the 70's. We are one foot in the grave already!
While I appreciate your passionate concern about the future decline of the hollow-state electronic device industry, as long as there are guitarists out there, tubes aren't going anywhere soon. Tubes are relatively common in guitar amps for their overdrive characteristics and perceived "warmth", and as good as modern modeling software has become, it'll never be the same as using the real thing- they just "feel" different, which can be a good or a bad thing depending on style. Tube guitar amps are still in high demand, and as long as a demand exists for them somebody will find a way to meet the requisite demand for tubes. The only downside is the limited selection of types currently in production.
 
I would like to bring a product to market for a modest cost yes. I wouldn't do it unless I could bring a good product. The problem that I see with the industry is there are not a lot of places where you can go listen to/buy an affordable tube amp. Would like to have a polished product that can hit store shelves. Cnet surveyed users said 21% preferred vacuum tube audio - where are they getting it from? Most people my age or under don't even know what a vacuum tube is to begin with...

I'd like to bring modern chassis and controls to some tube gear. I want to "dumb" it down. That was one of the things retail beat into me my whole life was that you can't be technically over the customer's head - if they want you to speak nerd to them, they will speak it first. Every time I would talk about why something is technically better people would just look at me dumb founded. The DIY tube audio kit is something that probably 80% of the US population under 30 don't even know exist. 70% of them don't even know what a tube is.

It needs to be simple, like a shelf stereo system, (possibly even offered pre-packed with speakers) and it needs to be seen in a retail store... and it needs to be AFFORDABLE! BUT IT NEEDS TO FLAUNT ITSELF AS TUBE TECHNOLOGY! So it must appear and sound superior. The difference is, we can make it good. The US public is extremely brand loyal to those who treat them right - look at Apple.

I don't want to become a gajillionaire. I just want to find something I enjoy doing and make a living doing. I prefer bargain hunting to great wealth.
 
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The parts needed for tube amps are expensive. There's no getting around that. And, that's why you don't see good tube gear for sale to the general public.
A few companies have tried to get cheap tube gear on the commercial market (ipod amps, and things) but to get the price low enough for a normal person to purchase, they have to make extreme compromises, and the amp isn't worth purchasing.

There's no point in making consumer, mid-fi, tube gear, because of the cost. To do it right, you're going to need expensive parts, and as you can see from all the responses, a good amp under $200 is probably not possible.

I'd say 90% of your battle would not be in the circuit design, but in your components vendors. You'd have to find cheap affordable and decent quality transformers... good luck! Maybe start by designing your own high volume transformer winding machine 🙂.
 
Well, thats one way I was thinking about (in the future, pending on early success) expanding the business and driving the costs down. Start doing stuff in-house.

When I talk about how "uber-ambitious" I can get, I could only desire to (Eventually) start making US manufactured tubes again 🙂

Find a way to bring back the old black plate tubes and even improve on them with what we know about metallurgy today...

and then Nanotubes
 
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I don't want to become a gajillionaire. I just want to find something I enjoy doing and make a living doing. I prefer bargain hunting to great wealth.

If you are serious about this, then in order to accomplish the task, you are going to have to learn everythng you can about audio engineering, vacuum tube theory, tube amplifier design, product sourcing, manufacturing, etc.

Unless you are planning on hiring engineers to do this for you, you'll have to come up with this design yourself. I'm sure once you have a design on paper there are many here that will be glad to offer critique.
 
To make the most of my learning abilities, I'm going to try and build something as I'm learning it. Raided my goodie room (yes, room lol) for what might be useful and I've come up with the following:

Industrial power transformer - Don't know which taps are which but I can get anywhere from 60v to 230v out of it depending on the taps and this thing is HEAVY duty.

Sylvania D19 chassis power transformer - was made for an older tube TV, not sure what B+ totals up to but have the other voltages listed. Prob not much current on B+, will save it for a preamp

4x 1625 Pentodes
4x 12BY7 Pentodes
2x 12AX7
2x 12AT7
2x 250v 1000uF caps
2x 500v 330uF caps
and some others

O ya, will have an extra set of 6550's on Monday

Things I know I'm lacking - sockets and transformers (I have a few 12ax7 sockets laying around but no power tube sockets)
 
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Maybe up your budget a bit (say $300), come up with a simple design using something like a 12AX7A and pair of 6BQ5 per channel, set of Edcor iron, build a prototype and then go to kickstarter and see if you can get funded to do it.

A recent kickstarter success story is uturn audio which launched a couple of years ago (Boston area based) and makes the orbit turntable.

You do understand that it you want to sell this in big box stores you are going to need UL or CSA approval and this is going to be quite expensive. Even if you sell direct you had better still design something that cannot electrocute its user or burn down his/her house.
 
I have been making tube amps for over 50 years. I have designed dozens from scratch, and even sold PC boards and parts kits for some of my designs. There will be more coming in the future, and maybe some kits, now that I am "retired" from my 41 year engineering career at Motorola and have more time for tubes.

I feel that I am doing my part to keep the tubes lit, educate the next generation in the way of the glow, and make tube stuff accessible to the masses. I have designed some very low cost amps, and some that would cost a few K$$ to duplicate.

For the past 41 years I have worked as a design engineer on electronic equipment for the consumer market, the industrial, public safety, and military markets. Before that I ran the service department for an electronics chain store next door to the University of Miami (management called it the University of Money). I have spent years learning the in's and out's of the consumer electronics business and I don't see tube HiFi equipment being sold in a big box retail electronics store any time soon, if ever. Here it my reasoning.....

I believe that someone could build a usable tube amp for under $200.....in material costs. Then you want to get it into a big box store????? You will need agency approval (UL, CSA) and product liability insurance (good luck with that on a tube amp) before they will talk to you. Once you have it built, approved, and packaged for sale, that $200 is more like $400. Your marketing and distribution costs will be at least another 10% of the retail price, and retail markup in a big box store is at least 40% of list price, often more, so now your $200 amp sells for up to $800. Oh, a big box store will want some volume guarantees, and volume price breaks every year. This means the ASP (average sales price) will be lower every year to maintain volume, therefore your cut at the end (the $200) MUST go down every year. This is called the cost curve, and it is very hard to beat the cost curve.

Lets say you come up with a really cool gizmo that everyone wants. For example lets say it is the Motorola Razr Phone. It came out in 2004. It cost just under $200 to make, and sold to the phone carriers (AT&T, VZW...) for $350. The carriers sold them for $299 + another $250 in subsidy recovered from monthly contract payments. So we have a $200 gizmo selling for $550. Millions were sold. Each year (biannually or quarterly with phones) the carriers came back to Mot and said we will place a bigger order for Razr's, but we want them cheaper. To accommodate that, the engineers had to figure out how to make the Razr cheaper. Phone engineers worked 7 day work weeks and Razr's got cheaper for all involved. The Razr beat the cost curve for nearly every quarter. When it was discontinued in 2007 it cost Mot under $100 to make each phone. They were selling to the carriers for about $150 and the ASP (subsidized) was as low as $79 during Christmas. Note the drop in profit margin over time. $150-> $50 per unit.

The Razr was the last BIG phone success story for Mot. There were several follow on phones that did NOT meet the cost curve. There were also some that did not sell well. Mot is no longer in the phone business. And the 7 day work weeks is why I left the phone group 10 years ago.

This is not meant to scare you off, only to educate you in the reality of retail sales, especially through the typical big box channels. In case you haven't noticed, the big box electronics situation is changing.....Circuit City has died, and Best Buy keeps trying to reinvent itself. HH Gregg, well who knows, but if Amazon figures out how to drop ship large appliances, they're toast as well.

So, assuming you have developed the $200 tube amp that everyone wants, how do you sell it?????? Kevin may have the answer. Crowdfunding sites like Kickstarter accomplish two goals at once. They get you started with working capital, and provide some limited advertising. The secret to being successful with crowdfunding, is to have a working prototype, a plan to get it to market, a believable business plan, a "tell all" web site and most all, several ardent if not overzealous fans. If you go to crowd funding, and fail, you are done. Nobody will likely believe in you the second time, so get it right, and have your ducks in a row before you go there. I have seen several startups go from zero to hero through Kickstarter, particularly in the unique musical instrument business.

So, learn all you can about designing tube amps, make some for your friends. If they are good enough, they will sell themselves. The Tubelab TSE and the SSE got started this way. I made one for myself, loaned it to a friend who bought it.....It helped that I worked in a large electronics plant with over 1000 engineers at it's peak. It took me several years to saturate that market with tube amps. By then, I knew what people wanted. A college campus has the customers, they just don't have the $$$, unless it's the U of M!

Note, tube guitar amps are easier to sell, for a higher profit, but it's a more fickle market, it's got to sound unique.

Could I make a reasonable tube amp for $200. Yes. It would NOT use current production tubes. They are too expensive. There were 10's of million's of tubes produced. Find a type of tube that you can buy for $1 or $2 that everybody has thousands of in stock. Preferably one that was, and still is available world wide. They are out there. Find a source for cheap transformers. They are out there, but you have to understand what's really needed, and get a bit creative. This requires a thorough understanding of how all this stuff really works, and why.

Go read every post in the Hundred Buck Amp Challenge in the Instruments and Amps forum for cost saving ideas. I designed a $50 guitar amp that ROCKS!

Before you sell ANYTHING that plugs into a wall outlet, and generates enough voltage to FRY a customer, talk to a lawyer that understands the situation. Every case is different, but you will probably need to incorporate, and avoid selling a finished product (back to the approval, and liability thing again). That's just the reality in todays market. I won't even sell a COMPLETE KIT.

When I talk about how "uber-ambitious" I can get, I could only desire to (Eventually) start making US manufactured tubes again

I have talked to the largest user of vacuum tubes in the US. He has been in discussions with several groups, that have been attempting to restart tube manufacture in the US, and even tried it once, doesn't seem to be a possibility. The startup costs are insurmountable, and there are all sorts of regulatory issues with making things that haven't been made before (recently).

BTW, what tube were these guys looking to make???? Well, it was the RCA black plate 6L6GC. Why, because The current production comes from places where political stability is uncertain, and at times the quality is inconsistent.
 
Tubelab> Good to finally hear from you, was looking forward to when you came back. I have been reading profusely everything I can get my hands on about the minimite. The level of understanding you have of tubes is what I'm hoping to achieve to one day.

I certainly understand some of the retail aspects, and the continual pressure to make something cheaper, safety concerns, UL certification, etc. I've given a lot of thought to these issues, I just didn't really take all the time to spill out every detail of my plan here. Component costs will go down if there is demand and I can start ordering custom parts and also in bulk.

I have thought about going the Kickstarter route in order to get the business kicked off like others have suggested. As you said, the prototype has to come first.

There are many dangerous products in the world that are sold (or were sold in mass quantities) on the shelf every day. Tube TV's, LCD monitors, Plasma TV's, Neon signs, Fluourescent ballasts, HID ballasts, tube amps (if you go back to the 80's) theres tons of stuff you can pick up every day at Home Depot that can zap ya dead. I'm not discouraged by it, nor arguing with your expertise - you obviously know a lot about what you're talking about. I'll find some assistance in that department when the time comes.

The only reason I want to spec new tubes is for the very essence of tube amps - you can change how they sound by changing the tubes. The more choices available (even NOS available to the customer after purchase) the better I feel. Customization has kept Android competitive with Apple for their phones - for the power users (also on costs, but thats another story). In building a tube amp for the masses, I would like for replacement and enhanced tubes to be readily available as people expand their horizons in the hobby. To offer NOS tubes where there are limited brands or were not used in audio purposes kind of defeats the open architecture I hope to employ.

I'm still working through the business plan and the other bits (and everything that needs to be packaged in) and a lot of it I'm struggling to understand. What I'd like to have as a finished product:

10-20w preamp/amp combo
4 external analog sources, 2 external digital (SPDIF/TOSLINK) (1 phono too)
Dot Matrix Display (20x4 possibly)
remote control (or iOS/smartphone remote)
automatic bias control
electronic bass, treble, volume, bal controls available from remote
Airplay, Chromecast, and Bluetooth
Chassis with easy access to the tubes

and I certainly don't want to build just 1 model
 
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I have been making tube amps for over 50 years. I have designed dozens from scratch, and even sold PC boards and parts kits for some of my designs. There will be more coming in the future, and maybe some kits, now that I am "retired" from my 41 year engineering career at Motorola and have more time for tubes.

I feel that I am doing my part to keep the tubes lit, educate the next generation in the way of the glow, and make tube stuff accessible to the masses. I have designed some very low cost amps, and some that would cost a few K$$ to duplicate.

For the past 41 years I have worked as a design engineer on electronic equipment for the consumer market, the industrial, public safety, and military markets. Before that I ran the service department for an electronics chain store next door to the University of Miami (management called it the University of Money). I have spent years learning the in's and out's of the consumer electronics business and I don't see tube HiFi equipment being sold in a big box retail electronics store any time soon, if ever. Here it my reasoning.....

I believe that someone could build a usable tube amp for under $200.....in material costs. Then you want to get it into a big box store????? You will need agency approval (UL, CSA) and product liability insurance (good luck with that on a tube amp) before they will talk to you. Once you have it built, approved, and packaged for sale, that $200 is more like $400. Your marketing and distribution costs will be at least another 10% of the retail price, and retail markup in a big box store is at least 40% of list price, often more, so now your $200 amp sells for up to $800. Oh, a big box store will want some volume guarantees, and volume price breaks every year. This means the ASP (average sales price) will be lower every year to maintain volume, therefore your cut at the end (the $200) MUST go down every year. This is called the cost curve, and it is very hard to beat the cost curve.

Lets say you come up with a really cool gizmo that everyone wants. For example lets say it is the Motorola Razr Phone. It came out in 2004. It cost just under $200 to make, and sold to the phone carriers (AT&T, VZW...) for $350. The carriers sold them for $299 + another $250 in subsidy recovered from monthly contract payments. So we have a $200 gizmo selling for $550. Millions were sold. Each year (biannually or quarterly with phones) the carriers came back to Mot and said we will place a bigger order for Razr's, but we want them cheaper. To accommodate that, the engineers had to figure out how to make the Razr cheaper. Phone engineers worked 7 day work weeks and Razr's got cheaper for all involved. The Razr beat the cost curve for nearly every quarter. When it was discontinued in 2007 it cost Mot under $100 to make each phone. They were selling to the carriers for about $150 and the ASP (subsidized) was as low as $79 during Christmas. Note the drop in profit margin over time. $150-> $50 per unit.

The Razr was the last BIG phone success story for Mot. There were several follow on phones that did NOT meet the cost curve. There were also some that did not sell well. Mot is no longer in the phone business. And the 7 day work weeks is why I left the phone group 10 years ago.

This is not meant to scare you off, only to educate you in the reality of retail sales, especially through the typical big box channels. In case you haven't noticed, the big box electronics situation is changing.....Circuit City has died, and Best Buy keeps trying to reinvent itself. HH Gregg, well who knows, but if Amazon figures out how to drop ship large appliances, they're toast as well.

So, assuming you have developed the $200 tube amp that everyone wants, how do you sell it?????? Kevin may have the answer. Crowdfunding sites like Kickstarter accomplish two goals at once. They get you started with working capital, and provide some limited advertising. The secret to being successful with crowdfunding, is to have a working prototype, a plan to get it to market, a believable business plan, a "tell all" web site and most all, several ardent if not overzealous fans. If you go to crowd funding, and fail, you are done. Nobody will likely believe in you the second time, so get it right, and have your ducks in a row before you go there. I have seen several startups go from zero to hero through Kickstarter, particularly in the unique musical instrument business.

So, learn all you can about designing tube amps, make some for your friends. If they are good enough, they will sell themselves. The Tubelab TSE and the SSE got started this way. I made one for myself, loaned it to a friend who bought it.....It helped that I worked in a large electronics plant with over 1000 engineers at it's peak. It took me several years to saturate that market with tube amps. By then, I knew what people wanted. A college campus has the customers, they just don't have the $$$, unless it's the U of M!

Note, tube guitar amps are easier to sell, for a higher profit, but it's a more fickle market, it's got to sound unique.

Could I make a reasonable tube amp for $200. Yes. It would NOT use current production tubes. They are too expensive. There were 10's of million's of tubes produced. Find a type of tube that you can buy for $1 or $2 that everybody has thousands of in stock. Preferably one that was, and still is available world wide. They are out there. Find a source for cheap transformers. They are out there, but you have to understand what's really needed, and get a bit creative. This requires a thorough understanding of how all this stuff really works, and why.

Go read every post in the Hundred Buck Amp Challenge in the Instruments and Amps forum for cost saving ideas. I designed a $50 guitar amp that ROCKS!

Before you sell ANYTHING that plugs into a wall outlet, and generates enough voltage to FRY a customer, talk to a lawyer that understands the situation. Every case is different, but you will probably need to incorporate, and avoid selling a finished product (back to the approval, and liability thing again). That's just the reality in todays market. I won't even sell a COMPLETE KIT.



I have talked to the largest user of vacuum tubes in the US. He has been in discussions with several groups, that have been attempting to restart tube manufacture in the US, and even tried it once, doesn't seem to be a possibility. The startup costs are insurmountable, and there are all sorts of regulatory issues with making things that haven't been made before (recently).

BTW, what tube were these guys looking to make???? Well, it was the RCA black plate 6L6GC. Why, because The current production comes from places where political stability is uncertain, and at times the quality is inconsistent.

Very wise advice, especially about liability. An LLC is a must.
 
Tubelab>...What I'd like to have as a finished product:

10-20w preamp/amp combo
4 external analog sources, 2 external digital (SPDIF/TOSLINK) (1 phono too)
Dot Matrix Display (20x4 possibly)
remote control (or iOS/smartphone remote)
automatic bias control
electronic bass, treble, volume, bal controls available from remote
Airplay, Chromecast, and Bluetooth
Chassis with easy access to the tubes

and I certainly don't want to build just 1 model

What you would like to have is irrelevant.

What does your market say they want, and what pricepoint are they REALLY prepared to meet for it?

Tubelab and others have said the rest.
 
What I'd like to have as a finished product:

10-20w preamp/amp combo
4 external analog sources, 2 external digital (SPDIF/TOSLINK) (1 phono too)
Dot Matrix Display (20x4 possibly)
remote control (or iOS/smartphone remote)
automatic bias control
electronic bass, treble, volume, bal controls available from remote
Airplay, Chromecast, and Bluetooth
Chassis with easy access to the tubes

and I certainly don't want to build just 1 model

It seemed very unlikely (at least to me) that you could sell a basic tube amp at the $200 price point and still turn a profit. But after adding your extra features, it feels even less likely. That is quite a bit of extra electronics. Looks like you'll need a decent DAC chip along with a fair amount of digital bits to tie it all together. Plus extra power supplies... Maybe source ultra-cheap parts from China to fill the bill?

Don't forget there will probably be licensing fees to incorporate Airplay, Chromecast, etc.
 
The finished product won't cost $200... I just needed to see if the concept was possible to make a simple pre made amp for around the cost of an iPod (which is around what people will pay for systems from a reputable brand - i.e. Big Jambox, the huge Beatsbox, Bose, etc. It was just the figure I came up with in my head for the costs. I don't know what anything would retail for at this point... there's still much work to be done. Ideally, I would like to have a complete system (pre-amp/amp combo and a pair of decent speakers) far south of a grand. I know I wouldn't be able to offer anything to the market for $200 at this time... but later on, I'd love to see just how low I could push the price point on a decent, but low powered tube amp.

Things that connect to their iGadget is what people want.
 
Nope. It isn't even achievable.
From a technical POV, after having read the S.e.x. review, it takes the same demanding time to make an equipment that should perform like...
Well >500$ is what you get; low DF so speakers that might need the impedance contour curve or might like it...
So many people involved in the low tube power & high efficiency speakers
which becomes for simplicity a 15 " & driver+horn 🙄
But with an expense of a tube more and a tap on the primary it could deliver double watts and that becomes interesting 🙄
But, returning to the program source, if it "cuts" -literally the lows & the highs-
part of the original sound, read compression and decoding- no real expense of time & research for making anything more than "it sounds...good" "fair" "acceptable" 😕
 
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