> idling at 22mA then playing watching the meter I can see the mA's going up...
That's what happens. At FULL power, a 400V 8K amp will pull 120mA sine, 170mA square-wave (or gross overdrive distortion). Whether it idles at 5mA or 25mA doesn't really affect the FULL power condition.
And you didn't build it just to watch it idle.
So why care? Because as you come up from silence, or for guitar as you fade to silence, as you come down below ~~1 Watt the idle bias controls the gain and distortion.
> sometimes they don't have the harmonics as tubes about 5 to 10 mA off.
Yes, you'll get a rise in even-order harmonics as the power fades.
> I can hear tubes that are 15mAs or more off from each other
It's relative. When we ran 6V6 at 250V near 50mA, I doubt you would hear a 40mA/55mA or 38% mis-balance. When you have 5mA/20mA or 400% unbalance, assuming you play/listen in the soft zone, that's significant.
> those testers not being that great, I calibrated the tester but those resistors and pots are old
It doesn't even test the tube as an amplifier.
Look. Say I build a "Clarinet tester". All it does is blow a fan down the pipe and read the flow. If there's a sock jammed in the bore, the meter shows "dead"; if there's a half-inch of scum in the bore it reads "low". And of course a scummed-up clarinet has a problem. But if it reads "90%" flow, or "140%" flow, is that good or bad? Some players don't use full flow, they just don't need full flow. Flow is not "tone": clarinet makers tweak the bore for a tight or loose voice. My "tester" doesn't even say if a clarinet actually PLAYS, or if it plays like a frog.
> I take the results like a grain of salt.
Bucket of salt.
The shorts-test is valuable. If you can see leakage in a dark room, that's bad. Seeing the heater light-up is re-assuring.
Then I tap the TEST button. If nothing happens, hmmm. Check settings, try a similar tube. If the needle does move, and may wind-up near the green zone, that's good enough. The test condition (ALL non-cathode parts tied together) and the test voltage and target current are totally bogus for audio amplifier work.
> At least I could tell if they were weak or strong
I don't think this type tester even tells you that. Remember the Grid is the input and the Plate is the output... but this tester ties both TOgether! A tube with a dead plate and a grid that really sucked (or a weak plate and sucky grid) could read "OK" even though it would be useless (or poor) as an amplifier.
And tube sellers hate these things. The tester may expect 12AX7 to gush 3mA at 60V. Some tubes may "fail" that, but easily pass 1mA at 200V, the way we use them in an amplifier. Moreover, these bogus target currents were picked for cheap simplicity, and "may" exceed tube ratings. Prolonged leaning on the TEST button may damage perfectly good tubes. Some vendors (including our host) decline to replace "bad" tubes tested in these low-cost testers.
The only real test is in the actual apparatus.
A wide-open Champ with a few extra sockets will test most gitar-amp tubes in real-life conditions. To calibrate, run a handful of probably-good tubes through it. Go by the sound and the electrode voltages. Say five out of six 12AX7s read 170V-195V at the plate, one shows 110V and sounds different. That's your "good" zone for 12AX7. 12AT7 will be less-loud and may show 100V-130V at the plate; anything else is dubious. The 6V6 hole will take 6L6 and 6550, give cathode voltage a little different from 6V6 but pretty consistent for each type. Jump in 1 to pin 8 and you can test EL34. Add a 9-pin socket to test EL84 and 6AQ5. EL84 in a 6V6 bias will read a lower cathode voltage, but 95% of not-sick EL84s will show the same voltage within 30%.