Armed now with a NanoVNA, I took a look at the passband of the 5 MHz filter in my Barebones Superhet (BBRX) W4OP built it on a Circuit Board Specialist Board. He put a 5 MHz CW filter in there; I broadened the passband for phone by changing the values of the capacitors. Here is what the passband now looks like in the NanoVNA:
This is what DeMaw would call an "LSB filter." You would get much better opposite sideband rejection by using it with an LSB signal, placing the BFO/Carrier Oscillator slightly above the passband, in this case near 5.002 MHz.
When I first built the down converter to get the 18.150 MHz signal down to the 7 MHz range (where I had the receiver running) I used an 11 MHz crystal for the NE602's local oscillator. But this created a big problem: 18.150 - 11 = 7.150 MHz. That is in the 40 meter band, but note: NO SIDEBAND INVERSION. Then in the BBRX 7.150 MHz - 2.150 MHz = 5 MHz (the filter frequency) but again: NO SIDEBAND INVERSION. The signal started as a USB signal and remained a USB signal.
I briefly tried shifting the BFO frequency to the other side of the filter passband. If I could get it to around 4.985 MHz, it might work, but because the filter passband was so large, and because the crystal frequency was so low, I was unable to shift the crystal frequency that far. In any case the results would have been less than ideal because of the "LSB" shape of the filter. Back to the drawing board.
I decided to cause one sideband inversion.
At first I put a 25.175 MHz crystal module in my down converter. This shifted the 17 meter phone band down to the 40 meter CW band. It worked, but I cold hear strong 40 meter CW signals being picked up by the wiring of the receiver (the box is plastic!). I went back to the module jar in search of frequency that would move 17 meter phone to the 40 meter area (so I would not have to re-build the BBRX front end) but outside the actual 40 meter band.
I ended up using a 25 MHz crystal in the down converter. 25 MHz - 18.150 MHz = 6.85 MHz WITH SIDEBAND INVERSION. After checking on the NA5B Web SDR to see that there are no strong signals in the 6.835 to 6.89 MHz range, I retuned the output circuit on the converter and tweaked the input capacitor on the Barebones. I shifted the VFO frequency down to 1.835 to 1.89 MHz and put the BFO at 5.002 MHz. The receiver was inhaling on 17 meter SSB.
One more change to the BBRX: in his June 1982 QST article, DeMaw warned that trying to get speaker level audio out of the 741 op amp that he used would result in audio distortion. And it did. So I put one of those little LM386 boards I have been using into the BBRX box. I just ran audio in from the wiper of the AF gain pot. It sounds good.
In effect this is my first double-conversion receiver. I usually prefer single conversion, but this project has highlighted for me one of the advantages of double conversion for someone like me who eschews digital VFOs: Starting with a crystal filter at 5 MHz, with double conversion I could keep the frequency of the LC VFO low enough to ensure frequency stability. That would have been impossible with a 5 MHz IF in a single conversion 17 meter rig. But if I were starting from scratch for a 17 meter rig, I could stick with single conversion by building the filter at 20 MHz, keeping the VFO in the manageable 2 MHz range.
Now, on to the SSB transmitter. The Swan 240 dual crystal lattice filter from the early 1960s needs some impedance matching.
