Turns out the S-W had some additional problems.  I had noticed before that the audio sounded sorta distorted on stronger stations but really didn't dig into it before because of the weak tubes.

http://www.nostalgiaair.org/PagesByModel/359/M0020359.pdf

So I started investigating.  Turns out the 300 ohm flex resistor on the RF amp cathode was open.  I had overlooked it during triage since it was inside a long piece of spaghetti.

Fixing that brought the RF amp up to some real gain.  But, alas, more distortion even on weaker stations.  More investigation revealed the RF Amp screen divider resistor (23) was also way high/ basically open.  I had checked it before.

Still no cigar.  I backed off on one of the IFs and noticed the audio cleaned up if I detuned it sufficiently.  Hmmm, AVC.  I had checked AVC voltage at the tone ctrl and had seen the RF amp cathode voltage going up and down and had assumed it was ok.  Wrong assumption.  Doh, that darn bad *volume control* was open on the through path!

I have a cheapo chinese one tacked in temporarily and the radio sounds GREAT!  This is a hot radio. 

Looks like a set of knobs is going to be the biggest problem on this project.  The Oppat generic wooden ones have apparently disappeared from the market and Mike Koste didn't have anything to offer.  Might have to get out my whittling knife!