Ed: My build has been a PITA from the beginning . But this build I have now was never right . See since the only chassis I had was from a fried 77 fender MM bass amp same size as a SF champ . Not knowing much at all I looked through fender schems and thought well the 5E3 weber eyelet board will fit but tight not knowing at the time I could have built my own eyelet board which in later builds I did. What I never considered was how the 5E3 would sound like and I hated it, it just looked like a simple P-P build with a rect tube . I searched for better iron and then saw Allen Amps site and though well if I buy the TP25 and then the TO25 I have the choice of 6v6's or 6L6's . So I though I can build a high powered 5E3 and with the 6L6's and 2 100 watt eminence twleves it was much better than 6V6's , cleaner and louder yet it still over reacted and acted like a 5E3 ( low clean till 3 and then high OD past that). I did get the Allen amps trannies when I first did this build.
So to answer you . All I can say is looking at later fender schems it struck me the difference in the 5E3 seemed to be the dropping resisters . I then read about screen voltage and plate voltage and then looked back at the 6G2 and also the AA964 . I still had the harsh OD sound and not much else changed. So I took a risk and paralleld two 5K resisters with the one 5K just to get an idea what the actual plate to screen would be then figured I would go for the 1K dropper then add another filter cap and dropper to the preamp stage like the AA964 has. So now I guess my OD is more from the preamp section since now the screens are not sagging . Yes I have the fender style knobs like used on all BF and SF amps 1-10 . There is one more thing that changed . Before the amp would breakup near 4 no matter how light my pick attack was, worse on chords but even on single notes . Now it just begins to breakup at 6 1/2 on chords heavy pick attack but if I back off on the attack the breakup stops and on single notes or double stops and bends the breakup is slight until I crank it up to 8 then if I dig in it breaks up but in a smooth way and if I back off the attack it's clean again so the entire amp has changed . It never reacted to pick attack much at all before. To compare before to now ,it's was like using a full blown distortion pedal cranked as it acted before to a dailed back OD pedal now when it breaksup. I will point out I still use a 12AY7 for the preamp tube , a 12AX7 would probably only make the breakup come in only at a lower number but would be just as loud at a lower number so no point in doing that. The best part since I play blues is I can dial in the vol I want and clean it up or break it up just by pick attack alone . It is not really a bedroom amp because I would need an OD at low levels . At 4 it is pretty LOUD now yet since the vol doesn't over react as it did before if I do bump it to 5 it's just a bit louder at each number so I can get enough breakup to get clean tone and dig in and have enough breakup to dig the blues. Where this build really shines is at 8 , it just sings and even at 10 it still sings. AS a bonus I can used the strats vol and tone since they now have a wide sweep so I can turn the amp to 8 and back off on the guitar vol and get the same breakup at a lower level same with the tone controls on the strat. The strat now on 5 the tone does not change where before I would just drop the vol to 9 and the tone changed to dull and forget the tone pots on the strat they were treb or muffled by one number now it's gradual and useable . My champ build worked well with the strats but not this build it sucked so I left the strats full up .
I wish I could say what mathmatically changed all I can offer is it had to be the 6V6's that were producing the OD in a bad way. There is a direct relationship between the plate and screen I read this on Aiken in the bias section. I guess I prefer preamp breakup to output if what I have is true.
I tried everything I could think of at the time and even tried a BF tone stack with VOL, TREB and BASS and all that did was kill the tone to bland. So from that frame of thought sort of proves the OD I had was in the output section because even with that stack it still had the harsh OD all it did was allow me to turn the vol up more to get there. I would say now my build is a loud version of a AA964 closer to a BF deluxe . Another odd part is the speaker in this build is a weber sig 12S alnico 25 watt and it holds up well solid bottom not flabbing out and I still have the NFB switch and don't need it now , maybe if I used the 12AX7 it might work ok or if I change the NFB to what the AA964 has yet that seems to be more NFB and perhaps works better with the BF tone stack .
So there it is , a VERY long answer to a short question as usual for me. sorry .