I don't think solder is permitted for earth ground connections officially, because of mating cycles and flex of the ground pin if the cord is fucked up. The solder lug on the chassis is a bit more acceptable because that point is not being flexed, but you obviously still need excellent strain relief so the motion does not transfer through the ground wire from the plug (which is less if you use multi strand wire).
and the earth solder joint in the lower picture looks down right suspicious. I think you should at least make a half hook through the hole to solder it with good clearance to the pin if you insist on soldering it, it looks like its bearly attached. Did you clean and flux the joint (perhaps with a brass brush?). The wetting on your solder joints looks horrid but I am not sure if its a camera thing.
I agree: the earth should be crimped, but there's no flex. It's connected to the mains via an IEC connector.
I can't remember whether I wetted the joints, as this was well over ten years ago.
Also, where are the fuses at?
They're in the black holders which aren't very clear on the pictures.
cant hurt to put the levitating rectifier on a bracket either.
I agree, it might come off, if dropped.
Also would recommend a softer dielectirc between the torroid and the tensioning washer.
If I remember rightly there is a rubber or foam washer between both the large tensioning washer and the other side of the toroid but they're not visible on the photograph.
also are those earth ground lugs star washered?
I doubt it.
This one is unnecessary but there is a kind of cheap trick to wire-pcb junctions, where you drill a hole away from any conductors and zip-tie the wire to the PCB through the holes or between the hole and the edge of the PCB. It works very well I had a hobby project that got yanked very hard and it held up fine without damage to the PCB.
I don't know what you mean. I'm not familiar with that.