Let's assume I am wrong about the resistors being the noise source.
The Tone Stack of this amp is over-complicated compared to a Fender 2- or 3-knob tone stack (lots of extra resistors/caps). The output of the Treble control feeds a 50pF cap at the
wiper of the Volume pot. That seems like it could leave a bunch of hiss while chopping out all the meat of the sound. The effect would be worst when the Volume is very low (which could be partially the source of PRR's question, "Does it hiss on-stage with an audience??").
Let's guess the Dano tone circuit holds no magic, and rebuild with the tone stack of a
Deluxe Reverb. Be especially sure to copy how the output of the DR's Treble pot goes straight to the outer-lug of the Volume and not the wiper.
How's the hiss now?
How many noobs do you think you've run off over the years? Hundreds? You think ridiculing everyone who dares to ask a noob question is healthy for this community?
I am sorry for my comment.
It was intended in the spirit of, "all evidence is contradictory, the problem seems like it couldn't occur, therefore something is being overlooked."
I have to apply the same self-criticism when I try to troubleshoot something I'm working on or built: if it's not working properly and "
I've checked and everything is okay," then the only possibility remaining is that I am overlooking something. I have to ask, "
how did I screw this up," or the problem never gets fixed.
HBP, you didn't even read my whole OP before you started telling me how I was wrong.
... doesn't seem to be affected by swapping in a couple new components at a time (metal film resistors and Mallory 150 caps). I didn't leave the new ones in place if they didn't seem to make a difference, so it's (mostly) all still original components with some new solder. ...
Hiss usually comes from resistors, and I interpreted your statement above to mean a few resistors were replaced but the originals were put back in before moving on to trying a few other resistors. So what happens if 5 or 10 or 20 noisy resistors are present?
If the amp is worth keeping, the tone-stack re-dux above doesn't solve the issue, and there is no scope or other tool to isolate the source of the noise then it may be easiest to replace all the resistors and pots.
... Could a sketchy ground connection cause an ocean of hiss? ...
Normally, no. See the
tube amp debugging page.
An exception might be 60+ year old Fender amps with the brass grounding plate. Because it and the chassis are dissimilar metals, they develop corrosion over time. Techs solve all manner of noise problems by not-diagnosing and skipping straight to removing the pots & brass plate, then throughly cleaning the chassis & brass plate with an abrasive before reassembling & re-evaluating the amp's noise.
I don't know that your Dano has a comparable connection anywhere. If it doesn't and the resistors are excluded as a source, then that seems like more support for the tone stack being the cause of hiss.