I spent a lot of time on the road today and got my teeth cleaned. My father called me in the evening to report that the solder blobs inside the case aren't the cause of the sparking, but the result. Apparently the bearing on the antenna side butterfly capacitor on the MFJ-945E is shot and the plates are touching at about 100 watts and sparking up inside the tuner, melting bits of aluminum off in tiny blobs. He'll be sending an e-mail to MFJ tomorrow to see how resposive they are. I'll be keeping track here.

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