I hate wiring up boards in tweed chassis
Same here. I always wire my boards first then it's just a matter of connecting it all up. I think Slucky said he actually trims the wires, tins, them before setting the board. which is not a bad idea.
You're almost getting into a production-footing for some of these models (especially the Princeton Reverbs!). Here's something I never implemented because I wasn't producing in high-enough volume, but you might consider:
- If the chassis & components used won't vary (i.e., they are consistent in size from build to build), then you can standardize the placement of holes for board/transformers on your chassis, without deriving them each time. So this amounts to a standard chassis drilling template.
- The follow-on of that drilling template (and the point of this post), is you can standardize the length of each wire running between the sockets/board/pots. You'd have to do a build with sufficient, but not excessive, slack in each wire. Then disassemble your build, measure the wires, and for future builds use cut-to-length wire for each run from board/sockets/pots. Works really well if you're using push-back cloth wire.
- Individual wire lengths in the prototype build will likely be all over the place. However, you'll naturally find a smaller handful of lengths that work and can replace several slightly-shorter wire lengths found in the prototype build.
I know Fender (and probably Kendrick, Victoria) did this with vintage and modern tweed-style amps. And the biggest hassle of wiring sockets/pots of a tweed chassis (when the board already had the wires attached) is cutting to length & stripping in the tight space available to work. If you use the cloth push-back wire (the real stuff available from Hoffman, rather than the fake stuff from AES/CE Dist), you eliminate the stripping issue. If you've already standardized the wire lengths, you eliminate the time & waste of cutting wiring to length.
After that, a tweed build is
all about figuring out a workable order-of-install to make things easier. I bet you noticed installing the board would have been easier if you don't install/wire the pilot light until the board is bolted down. In some cases, a pre-wired pot assembly is best dropped in after the board is bolted down, but the sockets have to be installed with their heater wiring done before the board goes in.