This did help! Now I found the missing 40 dB... I posted some pics:

Duplexer pics
<http://conturafm.mine.nu/photo/photo_thumb.php?dir=68616d726164696f2f72\
657065617465722f6475706c657865722f41464c>

In the folder "pass-reject readjusted" there's a picture of the view
with the 40 dB hidden and how it looked after lowering the ref level.
Many thanks for this tip. This is the duplexer leg that I have already
readjusted for our freq.

Concerning the insertion loss I'm still confused. The procedure is clear
to me now, but the result is so far off of what it should be that
something must still be wrong. In the folder "insertion loss factory
condition" there are pics to show what I mean. The measured leg is the
one that is still in factory condition and has a passband of 425-430 MHz
at an insertion loss of 1 dB, according to the factory, and it has not
been worked on previously. As suggested I did first connect the cables
together with a double female and got 2 dB. This is quite a lot but you
see that the resulting insertion loss is still far off 1 dB. What the
heck?

In the third folder there's a picture of how that duplexer looks from
the inside. On the right side you see the removed cover of the cavity
flipped over. You see on the far left the adjustment studs, there are
big ones to adjust the frequency and in between there are small ones.
Does somebody know duplexers of this kind and can tell me what the small
ones are for? I could not see any effect in any way when moving these.

73
Martin

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