Here’s how to recreate the wide-ranging Epiphone Tone Expressor system on your guitar.
Hello and welcome back to Mod Garage! This is the second part of the Mod Garage look at the Epiphone Tone Expressor system (Pt.1), which is found on the Al Caiola signature model that was built from late 1963 until 1969. After discussing the individual parts and settings last month, we will now bring it all together and see how to use the system in a modern guitar.
In general, it’s possible to use the Varitone/Tone Expressor system in any electric guitar as long as you have enough space to squeeze all the stuff into it. You can mimic a lot of different pickups with this system, but because it’s designed for guitars with humbuckers, that’s how it works best. It’s also possible to use it the other way around and thicken up single-coil pickups instead of slenderizing humbucker tones, and in a future column I’ll talk about what I like to call the “reverse Varitone” system.
For a good and simple overview about all the details from last month, I decided to use a technical drawing to show the isolated Varitone system, so it’s easy for you to identify the individual parts:
Diagram courtesy of SINGLECOIL
This is the basic structure of the Gibson Varitone system with the original values Gibson used. The inductor is a 1.5 H choke. The Epiphone Tone Expressor system is identical but uses a 15 H choke as an inductor. There is a second version of the Tone Expressor system found on the Al Caiola model using the same structure but with different values for the parts. I think this was because different pickups were used, so here are the values for the version of the system in the Al Caiola guitar:
• 15 H choke as an inductor instead of 1.5 H
• Replace the single 100k resistor with a 33k resistor
• .0033 µF cap is used instead of the .001
• .01 µF cap is used instead of the .0033
• .022 µF cap is used instead of the .01
• .047 µF cap is used instead of the .03
• .1 cap µF is used instead of the .22
For best results, use the original Gibson Varitone values along with PAF-style humbuckers—the second version will work best with mini-humbuckers or similar pickups. Depending on the pickups you use, you can experiment and make your own custom version out of it.
“You can mimic a lot of different pickups with this system, but because it’s designed for guitars with humbuckers, that’s how it works best.”
The differences are:
• Using a 15 H instead of the 1.5 H inductor will shift the notches of the filters created by the Tone Expressor system down approximately a fifth for a fuller and fatter tone. Because it is possible to combine several caps with this wiring, choosing a 15 H inductor was also a clever move to keep the tone clearer and more present. You can experiment with this, too. A choke with something between 7 and 10 H will be in the middle of both versions.
• Using a 33k instead of the 100k coupling resistor fits pickups with a lower output like the mini-humbucker perfectly, while the 100k is great for pickups with more output like a PAF.
• The different cap values also correspond to the combination of different pickups and chokes, e.g., for a twangy, Telecaster-type tone, you need a 0.22 µF cap along with a PAF humbucker, while a 0.1 µF cap will do the same along with a mini-humbucker.
So, here we go with the Al Caiola wiring, starting with how it looks in the original guitars from the ’60s. You can clearly see the big, silver-cased choke on top of the electronics as well as the caps, resistors, and the individual switches.
Photo courtesy of Bonfires Vintage
And here is the drawing of the Tone Expressor system I made for you:
Drawing courtesy of SINGLECOIL
All switches are DPDT switches, the tone and volume pots are both 500k audio, and the tone cap is 0.022 µF. A is the coupling resistor (33k or 100k), B is the five 10M ohm pulldown-resistors (one on each switch), which prevent popping noises when engaging a switch, and C is an additional 33k decoupling resistor on each switch that is necessary to decouple the switches from each other when you want to combine their settings. You don’t need that on the Varitone because you can’t combine several caps with the rotary switch.
Besides experimenting with the parameters of the choke, the caps, and the coupling resistor, you can enhance your tonal palette quick and easy by using a pickup selector switch that can engage both pickups together.
In closing, here is a scaled-down version of this wiring, in case you don’t want to use a choke or can’t find one.
Drawing courtesy of SINGLECOIL
As you can see, the coupling resistor (A) and the decoupling resistors (C) are removed. That’s because in the system with the choke (second order filter system), these are necessary, but without a choke, they’re not.
That’s it. Since we are still in the year of the Strat, next month we will have a look into the Fender Cory Wong Stratocaster, so stay tuned!
Until then, keep on modding!
This blendable passive system might be your single-coil solution.
Hello and welcome back to Mod Garage. This year, the Fender Stratocaster is celebrating its 70th birthday. Happy birthday, and all the best for your next 70 years! To celebrate, I chose a Strat as our guinea pig for this month. But everything we are talking about applies to all single-coil-equipped guitars.
Let’s have a deep look into what can be done to get rid of single-coil hum, which can be very annoying, especially when playing live. I’m sure you all know the situation: Your band managed to get an important Friday night gig at, let’s say, Bob’s Country Bunker. You and your bandmates arrive in time to set up your equipment, naturally with everything plugged into the same circuit as Bob’s popcorn machine, dishwasher, and sandwich maker. You plug in your Strat, turn up your amp, and there’s a loud humming noise coming out of it.
A single-coil pickup has one coil with six magnet rods and two bobbins holding everything together. It not only picks up the strings, but also all kinds of external magnetic fields generated by transformers and other electromagnetic devices. But when two coils are wound in opposite directions and are working together, the hum will get canceled. This is an old principle dating back to the beginning of the 20th century, and it’s how a humbucker pickup works. In the past, guitarists had to struggle with radio stations, fluorescent tubes, transformers, and the like; today, it’s more digital fallout and, of course, digital power supplies of all kinds.
The pickup industry created all kinds of hum-canceling pickups in single-coil shape, most commonly stacked and double-rail-style pickups. So, a humbucker pickup can be the ticket out of such unpleasant live situations. But all of these options generate a different magnetic field compared to a single-coil pickup, resulting in a different tone. The resonant frequency is shifted downwards a little bit because the ohmic resistance and inductance of the two coils are added together. The tone gets milder and warmer, with more midrange—you all know this tone. Splitting such a humbucker will sound more single-coil-like, but it will pick up hum again. Connecting both coils in parallel rather than in series will also sound more single-coil-like and is hum-canceling, but it’s not a real single-coil tone.
Using a reverse wound, reverse polarity (RWRP) pickup such as a Strat’s middle pickup will get you at least two hum-free switching positions (bridge+middle and neck+middle), but even this sounds different. Going active is another way to fight humming noises, and these special pickups sound more or less like a real single-coil, too.
But what if you don’t want to compromise? Is pure single-coil tone with no hum possible? Yes and no! It is possible to come close, but one day, a digital gremlin may find a way to annoy you to a certain degree. And there are extreme situations where only a humbucker will work.
One step in the right direction is shielding the pickups and cavity of your guitar. Shielding the compartment of a guitar the right way is a challenge on its own, and I will cover this in a future installment of this column. But even if all the shielding is done the right way, the sound of the pickup will be altered to a certain degree, which is the nature of the beast. And the shielding is always there, so you can’t switch between pure single-coil and shielded single-coil tone.
So, what about switchable hum-canceling for your guitar? This way you could have both: pure single-coil tone and hum-free operation when needed. And if this could not only be made switchable but also controllable, you could balance your tone between the two.
Here is a solution based on principles from Bill Lawrence, which my dear friend Bernd C. Meiser from the BSM company has refined in order to make it more controllable: a variable dummy coil.
“But what if you don’t want to compromise? Is pure single-coil tone with no hum possible? Yes and no!”
In simple terms, a dummy coil is an additional pickup that is identical to the other pickups but without magnets. It has a phase, but no polarity. A dummy coil accepts the electric signal created by the magnetic single-coil pickup and reverses it, which will remove a large portion of the hum. In the process, a very small amount of the treble signal is lost as well. However, this treble loss is far less compared to stacked or dual-rail humbuckers.
The specs of the dummy coil need to be close to the pickup you are complementing. So, any universal dummy coils advertised to work with all single-coil pickups will only work to a certain degree but not perfectly. Instead, it’s best if you order a dummy coil that matches your pickup. The company who made your pickup will know the formula, and a dummy coil from them will be super effective. If that pickup is from a larger manufacturer, you’ll need to find out specific parameters—wire gauge, wire type, number of turns—so a custom pickup company can make a matching dummy coil for you.
The simplest way to set up a dummy coil would be to connect it permanently, so it’s 100 percent active all the time. For more flexibility, you can add a switch to turn the dummy coil on and off. But the most flexible way is to use a pot to control the dummy coil, so you can dial in pure single-coil tone, 100 percent dummy-coil hum-removing, and everything in between—in other words, so you can balance tone and hum-free-ness depending on the certain playing situation.
To do so, connect a 0.01 uF capacitor in parallel to the dummy coil. The high-end frequencies will no longer pass the dummy coil and its inductance; they will be drained low-resistance to ground. For the bass frequencies, the capacitor is still high-resistance so the dummy coil is active. This way you will have humbucking functionality for the bass frequencies, but pure single-coil tone in the high frequencies—what a perfect and clever solution from Bill Lawrence. If you now connect the capacitor and the dummy coil to a pot, you have a controllable dummy coil as described above.
You can experiment with the capacitor value for fine-tuning your system; 0.01 μF is a pretty good value to start. With a smaller cap, you shift the humbucking effect toward the high frequencies and vice versa. A smaller cap means more overall humbucking (bass and highs) and a larger cap means less overall humbucking, with the high and middle frequencies staying untouched.
A Stratocaster is perfect for this mod because it has two tone controls. One will be converted to a Telecaster-style master tone control, while the other will become the new dummy-coil controller.
For a Stratocaster with three vintage flavored single-coil pickups, I recommend the following pot configuration (all audio taper): 250k volume, 500k tone, 500k dummy-coil controller. This way, in humbucking mode, the two coils are connected in series rather than in parallel, so the resonance peak will be dampened. The two 500k pots will help compensate for this. The 250k volume is always the way to go in a passive guitar system to ensure the best and most even control. The 500k tone pot can be a little bit over the top in pure single-coil mode, but simply roll it down a little and you are in the 250k ballpark—problem solved!
Here we go for the wiring. It’s not hard to do and mostly uses the parts that are already there:
Illustration courtesy Singlecoil
That’s it! Next month, we will talk about some alternative ways to service a Stratocaster that can be real time savers, so stay tuned.
Until then ... keep on modding!
John Bohlinger and the PG crew visit the Seymour Duncan pickup factory in Santa Barbara, California, where company co-founders Seymour and Cathy Carter Duncan began the business in 1976.
Seymour Duncan himself greets PG’s crew and begins the tour by talking about his early days in the pickup business. He started re-winding pickups for David Schecter, then jumped into the big time via a large order from Japan—doing all his company’s early flatwork by hand. He also recounts meeting and being helped by Bill Carson, a co-designer of Leo Fender’s classic early instruments, including the Stratocaster, and gleaning tips from the legendary pickup designer Seth Lover. Plus, he recounts his time with Jeff Beck, George Fullerton, Ted McCarty, and other heroes of guitar.
After talking with Seymour, Bohlinger and the gang move to the factory, where Seymour Duncan CEO Marc DiLorenzo takes the lead. Pickups—more than 1,300 different varieties—are still built by hand at Seymour Duncan. And 20 more new models are being debuted this year. “You know how guitar players are,” says DiLorenzo. “They never stop chasing tone.”
Derek Duncan, custom shop manager and Seymour’s son, shows Bohlinger where the raw materials and components are kept—all inspected as they come in before they are put on the shelf. He also explains how the company kept pickups shipping out through the pandemic, except for one month. After the stock room, it’s off to magnet wire testing, then production planning—a two-person operation that processes incoming orders to plan which pickups will be built when. Next up: the custom shop, where we see NYC bass pickups in process, followed by a stop at the magnet grinding operation—where Derek also started working for the company—and the magnetizing station, where alnicos get their charge. At bobbin assembly, raw materials are tuned into components for use in the winding process. Some ultimately get dipped; others get a wrap of tape before moving along. The winding machine, by the way, was purchased from Gibson’s historic Kalamazoo operation. Then it’s on to pickup assembly, and, from there, we get to see the wax potting procedure. Lead wires—two or four, depending on the pickup—then get soldered to bottom plates.
Finally, we stop in on Kevin Beller in the company’s engineering department. Beller has designed many pickups over his four decades at Seymour Duncan, and during our stop he was working on Jared James Nichols signature P-90 style humbuckers. The finale: the space where pedals and the company’s PowerStage pedal-sized amps are made, including the 700-watt model used by Dave Mustaine.