> Is it a stupid idea to build a single ended cathode bias 7591A amp?
1) Yes. 7195 and Kin are warped: high peak current, high hain at high current, low Pdiss for cheapness. Good for push-pull, bad for SE. Note the huge THD in the suggested SE condition; this THD may not drop much at lower power,
A pair of 6AQ5 will make as much power, lower THD, less B+ filtering, and MUCH smaller output transformer. That's the un-stupid way to go.
2) It can work dandy as a DIY gee-tar amp. THD may be flavorful. Cost/weight of OT may fade in DIY euphoria.
> it's hard to find a usable load line for class A that starts at 450V.
Sure, that's possible. Although there's no reason to go high-voltage.
Start with Pdiss. Round to 20W for hasty math (but re-check with 19W at the end). Knowing Pdiss and B+ we know max idle current.
600V at 20W = 30mA
500V at 20W = 40mA
400V at 20W = 50mA
300V at 20W = 67mA
200V at 20W = 100mA
The SE peak current will be double the idle.
600V peak = 60mA
500V peak = 80mA
400V peak = 100mA
300V peak = 133mA
200V peak = 200mA
Maximum possible plate current is limited by G2 voltage. Page 3 of Sylvania 7195 data shows max current for various G2 voltages. At the knee we see about:
400V 250mA
300V 180mA
200V 100mA
For simple power supply we would very-much like to have G2 voltage near or a little low of plate voltage.
200V on plate can only work if we have a ~350V supply for G2. That IS stupid.
At 400V plate we need 100mA peak and 350V-400V on G2 allows more than twice that. This can work. We'll need a lot of G1 swing, though probably no problem. There is the risk of overload damage when available current is twice what we need. Or we could provide a 200V-250V supply for G2. That will work well, but holding a fairly steady 225V from 400V with varying G2 demand is awkward to the point of being stupid.
The 300V condition seems reasonable.
A trial value of load for SE pentode is always V/I. 300V at 67mA is 4.5K load.
Power output, for power pentode, should approach 0.4*Pdiss or 8 Watts.
Using 19W Pdiss we must hold down to 63mA.
The very soft low-current end of a 7591 swing will distort "bad". THD numbers will be "high" even before 8 Watts. As long as we are being "bad", can we cheat without getting caught? A low-impedance load will suck more current, and we "gain" more on the top than we lose on the bottom, THD gets slightly more-bad, 13%, but the "11 Watts" number is impressive. But this is a bench-numbers game. In a real world of loudspeakers it isn't real meaningful.
250V at 80mA 3K to 350V at 54mA 6.4K. Err 20%-30% low impedance rather than high.
Hammond 125DSE can be wired 2.5K (yes, it will stand 80mA when worked 2.5K for guitar) or 5K.