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The VAC is assumedly lowering the voltage going to the power valves and therefore lowering their ability to amplify?
If that’s the case and you’ve changed all the glassy bits, then I suspect you are looking at one of the components that controls the power valve bias, the output transformer or the VAC chip?
Whilst you'll get more speaker distortion at high volumes, increasing the voltage in the power valves should allow you more clean headroom before you get distortion - you're effectively increasing the window of 'clean' amplification by feeding the valve more voltage and current to play with
I guess the thing to do is to try and and see if there's a window where you get more headroom before it starts to go into power valve distortion and speaker break-up territory
Can you take the VAC out of the circuit on the J20? ..if so, it might be worth trying that and seeing if you still get the same issue or it goes away? ..you can get some unpleasant sound artifacts with any form of attenuation and without hearing it, I'm wondering if that might be what you are describing as distortion, but taking the VAC out of the circuit would answer that
Running a load box is just another form of attenuation, so whilst it takes the speaker out of the mix, it doesn't say whether it's attenuation related
With the volume of the amp set at edge of breakup and VAC@20watts, the sound is what it is. When I turn the VAC down to 4watts there's a big volume drop and the sound gets cleaner. I compensate the volume loss with the OX's headphone volume so it matches. I can definitely hear the sound is cleaner. A LOT cleaner, and rather nice tbh!
Now for the breakthrough. Tonight I unplugged the reverb jack next to the extension cab out, removing the (whole?) reverb from the circuit? The VAC@20watts is about the same volume as before, but now when I attenuate down to VAC@4watts, the volume loss isn't as huge and the sound remains the same, probably how most of you guys hear it. Perhaps even a bit gainier.
Jesse mentioned something about this little screw on the reverb unit feeding more clean signal into the reverb or something, to match the 'bypassed' signal. I don't know what it technically does but I might have to experiment... Maybe it's set very low, and it only affects the VAC@4watt setting, feeding it with very little clean signal, and thus being a very weak/clean signal?? It puzzles me though, that unplugging the reverb unit resulted in louder vac@4watt settings.
The load box and headphones add many elements which could manifest the problem you’re trying to solve and adds a lot of potential problem areas where you can he getting distortion
The relative signal going to Reverb )vs clean) would change if you turned up the Reverb via the control panel and should not be impacted by the VAC
if you are always using the load box, why not turn off the VAC?
But anyways, I just double checked it with the actual Tayden 25 speaker and measured with my phone's db meter, playing the same open E chord with same force and turning the vac from 4watts to 20watts:
Without reverb plugged in: 92db - 104db (minor difference in tone between these extremes)
With reverb plugged in: 82db - 104db (82db sounds cleaner, 104db sounds the same)
I bet there's a logical reason for this that probably has something to do with the screw?
If you want to know if the amp has a fault, play it without the load box in the circuit