Dale PH-25 Introduction Manual

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Introduction

Congratulations on purchasing the Resistor Volume Knob that allows you to adjust the volume

on your Spirit Proton Pack by rotating a replica Dale PH-25 power resistor mounted on the side

of the Ion Arm.

A Spirit Halloween Deluxe Proton Pack (not included) shown with the Resistor Volume Knob

installed:

Here is a reference photo of a screen used pack:

Table of Contents

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Summary of Contents for Dale PH-25

Page 1 Introduction Congratulations on purchasing the Resistor Volume Knob that allows you to adjust the volume on your Spirit Proton Pack by rotating a replica Dale PH-25 power resistor mounted on the side of the Ion Arm. A Spirit Halloween Deluxe Proton Pack (not included) shown with the Resistor Volume Knob...
Page 2 There are only two parts, the replica resistor knob and the mounting spacer: Shown here with a real Dale PH25 resistor and the volume pot from the Matty Blaster or the Spirit Blaster Sound Board kits along with the two parts from this kit:...
Page 3 Pack Knob prep: The Knob is 3D printed and has “support structures” to enable the internal structures to be placed at the correct locations. I first use pliers and then a small straight screwdriver to pull and scrape the support structures out of the inside of the knob. This can leave a lumpy surface, but it is not visible once the knob is mounted.
Page 4 2) Remove the original knob Cut off this knob. It really isn’t a very good replica of the ideal Dale resistor anyway. You do not need to get too close to the surface since the knob is not molded into the shell, just heat staked/glued by a central shaft.
Page 5 3) Next remove the leftover post. I used a 3/16” drill to get that out and then a 1/4” to make the hole. The 1/4” hole is too snug so either ream that out, or just use a larger bit. I used a 5/16” bit and that worked well but made a larger hole than needed.
Page 6 Do a test fit and mount before gluing. Then glue the surface of the spacer that comes in contact with the shell and mount in the pack. You do not _need_ to glue it, but gluing will help hold the volume knob in the correct orientation and not accidentally allow the potentiometer to rotate when you try and turn the knob too far.
Page 7 5) Next, just press the knob onto the knurled shaft of the potentiometer. This does take some effort but making it easier would risk having the knob fall off. Now put the pack’s back cover on and you are done!