Hi Justin,
Belated congrats on the new job. Hope you don't have to deal with the suits too often. Corporate jobs sometimes come with unadvertised baggage, like guys in suits making outrageous promises to the customers. Good luck with all that.
Gotta wonder how long the '4001s lasted on a 110 Volt relay coil? Sounds like a borderline voltage rating to me. As if a 6AQ5 would care, after all? Tried using a TIP 50 and a PN2222 to replace the 6AQ5 a few years back. THEY definitely needed the diode, but it went across the TIP50, not the coil. Sure did increase the keying circuit's sensitivity below a half Watt. One tip on that, ditch the .01 disc from the 6AQ5 plate to ground before hooking the TIP50 collector there. The TIP50 will discharge the disc and surge-slam the TIP50 the first time you key it. CLue? Doesn't unkey until you replace the TIP50. Only had to learn that part of the picture once.
And LoneWolf, the small tune and load knobs work on LOW side ONLY. This setup was used only in the Warrior and the oldest smaller D&A linears. The ones that had three relays had a separate, small Tune and Load for LOW side ONLY. They did nothing on medium and high. Pretty sure your Warrior is the same on that count. It's a quirky setup that required three relays in the smaller Phantom and Maverick models. D&A abandoned the "3-relay" layout after only a couple of years for the smaller models, and thereafter used a different method for low side that only required two relays.
I'm pretty sure I posted a guide to identifying a "true" peak from a "false" peak on the Plate Tune controls in another post. Have you looked at the controls that DO work with this quirk in mind yet? Leads me to guess that at least one "Tune" control, (of the three that are active on Medium and High side) is going to the end of its travel, showing a "peak" with the plates either fully meshed, or fully apart. If so, this will put a crimp in the power you see. Just because you see a "peak" on each of the active Tune knobs doesn't mean it's a true peak. If each of the "no end-stop" controls shows TWO peaks, that one is functioning correctly. If it shows only ONE in a full turn of the knob, there's a coil out of whack that needs to be trimmed.
73
