Dave,
Let me prognosticate that there is a close by AM broadcast station that's
overloading your front end, desensing it to the point where you are getting
distortion accross the 160 band. Even though the roofing filter is narrow
and the O6 doesnt tune there, there may be strong enough rf to
demodulate/rectify enough energy to IMD your reciever.
In case you are nowhere near a large AM Broadcast xmtr this of course can be
ruled out.
Check your molex connectors for intermittant conductivity. The power chord,
others.
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