Thank y'all for the reply. My coconspirator Derek and I are VERY thankful there is a place like this to ping ideas around. I think we're in the right place when you say "I know from experience, twice, I'm a forgetful learner". :) Part of the fun of this project is NOT doing a kit, so we really have to learn the process vs. just following instructions.
Some more thoughts that might make our goals more clear...
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Sound level: We're very aware that 2x 6L6 amp is completely impractical for an apartment in San Francisco. We also have a 5w 5F1 Tweed Champ and a 15w Matchless Lightning that are already way too loud and have generated noise complaints. We must *always* play with attenuators, even with the 5w Tweed Champ. We use the Fryette Power Station 2 and the Tone King Ironman Mini 2, and play in the sweet spot attenuated to semi-bedroom volume, or go direct with the attenuators as reactive loads into IRs/headphones. The desire for a 2x 6L6 amp is because we want an amp with very high input headroom for pedals. The Tweed Champ and Matchless Lightning are both very nice cranked and then attenuated, but we want to build the opposite, and amp with insane headroom. If we were sensible, we'd probably be playing Roland JC-40s, Peavey Bandits, Quilters, or Strymon Iridiums turned to 1.5, but what's the fun in that!
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The cabinet: We plan getting the amp working, chassis-only, and then we'll order custom cabinets from Mather Amp Cabinet. He does a "tall" Princeton 1x12:
https://www.facebook.com/photo?fbid=1125332470823526&set=a.948974455125996 He said it should be fine, but to be sure we can send final measurements for the build and he'll make sure it fits. His work seems very high quality and very reasonably priced. I also like the "tall" idea because in my small apartment I'm fine with using more vertical space, I just don't want to use more floor space. We might even go with a 2x10 tall Princeton cabinet. Having a tall Princeton cabinet may also gain us some bottom end when we can be loud. :) i.e. it's not just a tiny 1x12/1x10 box, but we still save a lot of floor space.
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The chassis: We'll order a custom chassis from someone like Juicy Amps:
http://www.juicyamps.com/chassis.html The chassis will be Princeton-sized, but obviously the tube cutouts and PT cutouts will be customized.
So, I guess my main thing to gather from the feedback so far is:
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Make sure the total footprint of the PT doesn't hang OUTSIDE the dimensions of the chassis. Then no matter how tall the Princeton is, the PT wouldn't fit! I'll check that. We ordered the transformers already, they should get here any day, and I'm probably going to order a normal Princeton chassis, just so we can eyeball it and refine the chassis layout before ordering that.
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Make sure we really want to be silly and do a 2x 6L6 amp instead of something like a 2x 6V6 amp. Rob Robinette actually has a design for the Blackvibe but with 6L6s. But we are competitive engineers and I kind of like the ridiculousness of getting a 40w 2x 6L6 into a "tall" Princeton cabinet. We're so accustomed to using attenuators all the time that it actually is kind of liberating us to build a loud-as-hell-amp vs. an appropriately sized amp. ??? :)
Thanks for any feedback. Once we get going I'll make a thread on here to post pictures and track. We have a log going on
https://bit.ly/blackvibe if anybody wants to follow along or join!
–Ben and Derek