Problem with SB401 not gone. HELP

[Dan Pividal N4VET]

I thought I took care of a problem I am having with an SB401 but I didn't.
Problem:
1. When I first turn on the rig my grid fluctuates in the tune position.
    Sometimes grid stays at bottom of meter (near 0) and I only get about 10
watts
    output. If I turn up the level control grid shoots up and I am at 110
Watts output.
2. If I go to USB or LSB and key mike a few times problem seems to get better
when
    I go to tune position.
3. After rig is on for about 1/2 hour and I have been on voice the grid stays
where it
    should be.
4. If rig is used everyday problem is resolved.
5. When I first turn on the rig after a few hours off I hear a pop and see a
small spark
    off the side near where the glass meets the Bakelite on one of the 6146's.
    Does not do this again after the first startup. 6146's check out fine.
I have cleaned all contacts on the relay.
I have gone over all the boards and fixed all bad connections.
I have checked all tubes.
I have neutralized the finals.
I have checked for bad grounds.
Has anyone had this problem?
I can't be the only one.
I run the rig with an SB303.
Any help please pass it on.
Thanks,
Dan

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