Anyone have any ideas? Are our crude methods of tuning the duplexer 
too crude? 

 

I would say yes.  I've done UHF cans with my service monitor for the signal
generator (very adjustable) and an HT to receive it on, and been moderately
successful.  However, your individual mileage may very, if you are practiced
with this method of tuning, you can do quite well.  If this is what you have
to deal with, I'd try peaking the PASS part of the cans with a wattmeter
after you have done all you can with the signal source.  That should get you
the most through the pass port, though you won't know what the skirts look
like or anything, but you will get more power out.  Assuming that works,
then I'd go for the notch tuning again and see if you can get it close
enough.  It's tough without the right tools.

 

Good Luck!

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