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Need pro's advice on controller
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Replacement variable resistors aren't pricey - the crucial part is finding the right type. I'm not sure how to work this out unless it's printed on the resistor. Before powering up the soldering iron though, there's another couple of possible solutions. I noticed in the photo that there's a metal plate next to the resistor - have you checked the solder tabs aren't touching this? Shorts can cause all manner of strange effects. I would also suggest a substance I've seen used on theatre lighting boards. Can't remember the precise name, but it comes in a spraycan and is designed to clean sliders (which are basically a variable resistor that slides rather than turning), we had a lot of problems with imprecise lighting controls in the theatre group I'm with, someone sprayed this stuff into the board, worked the sliders a few times, then left it to dry (power off) for a few hours, it worked much better after that. Think it's known as switch cleaner or something similar, if you go into a decent electronics shop they should be able to help though - both with this and with finding the right type of replacement part if the spray doesn't work. Hope this helps!
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