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It also seems to me that on some of the metal portables, I had to turn the chassis a few degrees sideways as it passed the speaker. I agree that removing the tube first isn't the best bet, but if you think you can do it without busting the neck, it might be the only option. At least then you'll see what the obstruction was, and can work with it better on reinstallation.
I hope that all these suggestions aren't just going to frustrate you further...
Charles
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Collecting & restoring TVs in Los Angeles since age 10
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