1962 AMI CONTINENTAL 2  JUKEBOX RESTORATION


I have been looking for one of these for longer than I care to think about.
Actually I was looking for a Continental 1, the 2 has a different color scheme and no emblem in the front plus some other changes
Pretty much everyone who has seen the popular movie GHOST has seen this unusual styled jukebox.






Photo By Anthony R.

Here it is.  There is a critical item missing from this photo, the title display cabinet, sometimes called "radar"
The curved glass covered title cabinet mounts to the jukebox using a cast metal bracket which snapped in half.


Photo By Anthony R.

Here it is from the back, I am considering making a few changes including painting the door red  to mimic the plastic under the dome
It clearly shows that the white was touched up or totally repainted, there is white on the vent screens
Of course that assumes the factory didn't paint the cabinet after the screens were in place.


Here is that title board


Here is the very broken casting that attaches it to the jukebox, it is not only broken but twisted at the ends.
This most likely caused when the jukebox was moved, using the title board cabinet as a handle to tilt the jukebox back.

After some research I found these jukeboxes were shipped with braces to strengthen the title cabinet when moving the jukebox to a different location.
However these support braces have been lost over time once removed. If anyone reading this has them, please share the dimensions.

See below







Photo By Anthony R.

Here you see the credit unit, pre amp, amplifier, and power supply.
AMI used black molded non polarized line cords to connect major parts of the jukebox all of which have deteriorated.
The Pre amp and amplifier will have all tubes tested, those under performing will be replaced.
All electrolytic capacitors will be checked as will inter stage coupling capacious for leakage
These chassis will be removed early in the restoration process

Note: the jukebox is complete with the exception of the cash box door, cash box drawer and the coin mechanism / slug rejecter

UPDATE: all three missing items have been found!




Let the fun begin

The first step is
to evaluate it's condition. Since this is the first AMI jukebox I have ever worked on, I need to get a handle on what normal operation is.
First is it working? If not I needed to get it working, not necessarily well, but working. That way in taking it apart I'll know if something changed once back together I  have a 100 watt lamp wired in series with a porcelain bulb socket and outlet. First, I unplugged the amp which also disables the preamp.
Activating the jukebox showed no excessive current draw...good sign. The mechanism, was jammed.turned out the aluminum turntable mat was forced
into the record drum along with a record. The tone arm was also in on the wrong side of a micro switch. There was also a plug disconnected
at the scan switch box. I had to establish a credit and presto after pressing a selection button combination it loaded a record. Good start.
I was warned that most likely all non polarized ac cords used would be toast, and that was true. Though none shorted, the inner insulation survived on most.
Now for the amp, I plugged the amp into a B&K variable ac power supply which allows monitoring current draw while increasing it's voltage.
Turning up the voltage on the amp showed no excessive current draw. The amp works and plays. (turned out in mono later on this)
OK tests done for now.


Next up, evaluate the title board, besides the broken mounting casting.
Checked glass for heavy scratches after removing old tape and dirt stuck to it, glass is fine.
Removed titles and unbolted what was left of the mounting casting there. At this time also removed many years of dirt inside.
Couldn't test it's side lighting since the lighting is from fluorescent tubes powered  by the jukebox.

Removed the  dome, white and red/orange plastics. The red has totally faded out. I will use VHT nightshade see through paint so that the lighting under it can be seen. Tied down the tone arm since the whole assy can lift straight up.

Next I removed the amp and pre amp. It appears completely original, coupling caps and electrolytics are original
No signs of damage. All tubes will be tested an cleaned
Update: All tubes tested good. That's a relief as vacuum tubes have gotten expensive.
At the time of this writing the output tubes have sold for as high as $100 each (times 4).

After that some parts of the cabinet were removed, grill, screen, trims, cabinet top,and doors
The jukebox was placed on it's back to replace the steel wheels, with rubber wheels so our floors will survive
At this stage the cabinet went through some extensive cleaning. The cabinet bottom was painted along with the speaker board
The grill was a surprise, it's anodized gold. All photos I've seen usually show what appears to be aluminum.
I have been told this is the way they came.


Below will be some photos of the process


Here are a few of those line cords cracking and falling apart
In this case, the inner wrapped insulation on the wires is gone also.
It's really amazing that the outer insulation failed in such a way that the wires did not short.
AMI used these cords to connect various components in the jukebox with power.
Update: All these cords have been replaced with new non polarized cords





First record to play on the jukebox, in how long?
Maybe 40 years, will have to check all records in the machine for dates to get a better idea
The tome arm is not setup correctly.


 

         
                                                                                                        Grill propped against Seeburg 222 for color comparison

  
Here the cabinet top has been removed to be refinished







This is a photo of the crossover network, Two wires was cut and twisted together, the one in the foreground was not even connected.
This may have had something to do with the speakers possibly being out of phase when this was built.
But it doesn't explain why the right side was not connected at all.


Here the crossover wiring repaired and speaker reconnected.
After a little more cleaning, it was returned to the enclosed area accessed behind the amplifier and pre amp through a screwed in panel.
Note: You can see this area by removing the coin box and looking through that area.




 
                                                                                 woofer                                                                                                                  Midrange speakers

Tweeter (highs)
These are the three types of original Jensen speakers used




This is the restored top






      

          The left photo shows the underside of this dome trim in poor shape on the right are the parts that fell out removing the trim on the left


    
All the buttons cleaned  (31)



This is the selector unit. Not shown here, a pin was removed from one of the AMP-LOC connectors, 
also from it's mating connector. A molex connector has been added here (temporally). Original AMP-LOC connectors and pins seem to have been lost to history.
As explained later all selector lights were out, turns out they are in series. One out, there all out. This done to drop the 25-26 volts.
This explains why they are not very bright, as the bulbs used are 6.3volt (around 4volts each in series)
Possibly 3.2 volt bulbs can be used, though their life would be shortened and they have a shorter life span to start with. A dropping resistor could be added
As with other components, shown here, dirt and cigarette damage has been removed
I use a strong cleaner, Spray Nine, to remove that damage.


   

This is one of many crimp connectors used by techs in the past to make quick solderless connections when replacing parts
These are pretty ugly and all need to be removed. This process has started
Update: I have been told by a restorer that has done 50 of these machines that is how the factory connected parts.
So, I have halted removing them, they still are ugly.






Here the title cabinet (radar) and turntable cover have had 60 years of dirt and heavy smoking damage removed.
That cover looks pretty good here but there is some discoloration and minor chips, it will be repainted
The foil label will be replaced.




Here the red anodized effect of these have been re-applied, one was badly faded





Here the left door after damage repaired, texturing and repaint


    

This is what the rear cabinet looks like at this stage. I noticed there is one label upper right the needs to be replaced
All non- polarized cords have been replaced, with black non- polarized cords, including the main power supply cord.





The majority of the  decorative metal has been sent out for polishing a replating.

  
These were sent to Courtesy Metal



More detailed testing and repairs started  less amplifier and pre amp.
Sometimes the nation would eject right after placing a record on platter.
All switches were cleaned and tested, including cam switches. NO contacts to tested to show no resistance, NC contacts to show close to zero ohms
After adjustments and cleaning the machine became more reliable.
This machine has a feature that all of them don't have called  automix, a feature that allows extended play 7" 33 1/3 records to be played.
The final operational test was to put a 7" small hole 33 1/3 record in the rack and select it. It didn't work.
I was educated by restorer Zuddie Smith, that the platter and it's spindle appear to be setup wrong .
On this Jukebox, the platter by default is set to play 33 1/3 small hole records.
When a 45 rpm record is selected and placed on the platter it's detected by the jukebox and 2 things happen, 
it changes the playing speed and also raises the 45 adapter in the center.

Unfortunately. this jukebox did not do this. The 45 adapter was always in the up position, which is incorrect.
The reason for that  turned out to be the addition of a washer and large nut added under the 45 adapter to keep it up.
This was probably done because at sometime in the past, a nylon piece part of the platter assy was lost.
Without it, the center adapter would have stayed  down permanently not allowing the jukebox to play 45's
With the change that was made, it could no longer could play 33 1/3 records but could play 45's




    

This turned out to be part of the reason the 45 rpm to 33 1/3 conversion didn't work.
Turned out it's actually, 33 1/3 conversion to  45 rpm speed (automix)
This seems backwards, from a design point of view, since 95 % of the records were 45's that would be played.
Possibly the anticipation was the the mini lp's would take over the market?
It was also missing an extension piece (the replacement not show here) which normally allows the 45 adapter to lift up.
With this arrangement it was always in large hole 45 rpm mod and only play 45's.











More soon.

         
                                                                                                                                                      The wiring of the lamps above is not haphazard, from left to right this is how they are wired





There are a total of 5 Florescent light fixtures in the Continental 2. The wiring for these is not shown in the manual.
Above is basically how all of this vintage lighting is wired.
Starters used are FS2 and FS5