seems to be a lot of confusion in this thread, and with so much information, that is bound to happen.
i am going to lay out a test for you. do the tests the way i say, and post the results.
first, i wonder if you are using that MFJ870 correctly.
here is what each switch position will do:
FWD- displays the watts coming out of the device connected to the meter. (higher is better)
REV- displays the watts coming back to the device connected to the meter. (lower is better)
SWR SET- use this setting to calibrate the meter for checking SWR. (remember this doesnt actually tune anything)
SWR- after calibrating the meter, switch to this position, key the mic, and read SWR.
so, when you want to see the watts ouput, use FWD.
when you want to check your SWR, use SWR SET and SWR.
connect things like this: radio---- Astatic SWR meter---- TSamplifier------ MFJ meter----- antenna.
remember that when using an amplifier, you actually have two different SWR's to measure.
the SWR between the radio and the input of the amp, and the SWR between the output of the amp and the antenna.
so, put radio in AM mode, channel 20, mic gain all the way down. amplifier OFF.
set MFJ meter to SWR SET, key the mic, and calibrate the MFJ meter (dont worry about the astatic meter yet).
set MFJ meter to SWR, key mic and note SWR reading.
post that reading here.
now switch the MFJ meter to the FWD position. key the mic. note the wattage output. this is your radio's deadkey. post this reading here.
as long as the SWR reading was 2 or less, you can turn on the amp now. dial a watt off, and all buttons out.
now, set the Astatic meter to CALIBRATE postion. with amp ON, key the mic, and calibrate the Astatic meter.
unkey the mic and switch the astatic meter to the SWR position.
key the mic and note this reading. should be 2 or less.
post that reading here.
now, with amp still ON, set MFJ meter to SWR SET position. key the mic and calibrate the MFJ meter. unkey the mic.
switch MFJ meter to SWR position. key the mic and note the SWR reading.
should be less than 2. post that reading here.
now switch the MFJ meter to the FWD position. key the mic and note the wattage output reading. post that reading here.
turn the mic gain on the radio up all the way, push the orange button on the MFJ meter in so you are reading PEP watts.
key the mic and say a steady "ahhhhh" into it.
note modulated wattage reading on MFJ meter and post that here.
good luck on your tests, i think you might not have as many problems as you think you do.
LC