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Sax-Repair.Pdf CHAPTER 1 GENERAL SETUP OF THE AVERAGE SHOP When we speak of the necessary tools in the 21. Scrapers (hook and straight) average one man shop, we must bear in mind 22. Mouthpiece puller that the small hand tools, which comprise the 23. Small dent rods tool box layout of the average repairman can not be considered as part of the average shop Saxophone and Clarinet setup. 1. Screw drivers (large, medium and small) It is for the aforementioned reason that we 2. Spring punches must list the shop or stationary tools and the 3. Midget and regular hacksaw small tools in separate categories. 4. Screw extractor 5. Pad slick (small and large) Shop Tools 6. Crack slick Lathe-Preferably of the Atlas or Delta Variety 7. Oil Stone Bench motor (1, 2, or 3) 1/4 HP 175 0RPM app. 8. Spring hook Work bench 34” high, 3’ wide, 5’ long 9. Hammer Polishing lathe 10. Rawhide mallet Drill Press (Optional) 11. Pin vise Assorted Dent Rods 12. Bench vise (41/2” jaws, swivel base) Dent Plug Sets 13. Wood mandrels Trombone Mandrels 14. Post drilling jig Bell Mandrels (Trumpet and Trombone) 15. Screw blocks Bell Iron or Horn Stake 16. Leak light Vise (4” or 41/2” swivel base) 17. Calipers Compressor (Size depends on amount of pres- 18. Micrometer sure needed) 19. Hinge cutters Torch (natural or manufactured gas) 20. Pivot reamers 21. Pivot counterbores IMPORTANT TOOLS FOR 22. Pad seat reamers INDIVIDUAL INSTRUMENTS 23. Socket reamers IN REPAIR SHOPS 24. Ring machine Brass Work 25. Tenon repair kit 1. Set of tapered mandrels 26. Key swedging pliers 2. Dent hammers 27. Bunsen Burner 3. Straight mandrels 28. Soldering jig 4. Straight burnishers 29. Sax dent rods 5. Curved burnishers 30. Pearl sets 6. Bell Mandrels 31. Post drills and tap 7. Dent plugs 8. Dent master Brass Repair Materials 9. Hi-Heat torch 1. Sheet brass (.010, .015, .020) 10. Lathe 2. Assorted brass instrument parts 11 Bench motors (2) 3. Valve corks 12. Trombone slide mandrels 4. Waterkey corks 13. Assorted files 5. Valve felts 14. Assorted pliers 6. Valve springs, assorted 15. Tin snips 7. Waterkey springs 16. Bell iron 8. Solder (50-50) 17. Rod Holder (v-block) 9. Silver solder 18. Draw Plate 10. Soldering acid and paste 19. Set of carbon drills 11. Borax 20. Set of taps and dies 12. Buffs 13. Polish instrument is held on his left side out of his way. 14 Brass rod (1/2” and 1/4” and 1/2” round When assembling a saxophone, he can easily 15 Assorted brass tubing face his work and still be next to his parts and 16. Pearls tools, assuming that the mechanic is using a 17. JUNK PILE (it can’t be too big) saxophone mandrel to hold his work in the vise. This is a wise move since it gives the mechan- Taps and Dies ic the free use of both hands while the saxo- 0x80. 1x72, 1x64, 2x64, 2x56, 3x56. phone is held securely in place, thereby acting 3x48. 4x40. 4x48, 5x40, 6x40. 6x32, as a third hand. 8x40, 8x32, 10x32, 10x24, 12x28~, A bench motor should be placed on the 12x24, l/4”x20. right side of the bench, with an adapter for a grind wheel, drill chuck or a buffing wheel. This Reed and Woodwind enables the mechanic to do most of his work Repair Materials without having to leave his bench. 1. Sheet cork and bottle cork 1/64, 1/32, The gas line should come from the top of 1/16, 1/8, 3/32. the bench at the center. The hose should be at 2. Sax pads least 8’ to 10’ long to enable him to get around 3. Clarinet pads (brown and bladder) a saxophone or a trumpet, while it is held in 4. Flute and piccolo pads place in the vise. 5. Flat felts The lathe should be placed to the left rear 6. Flake shellac of the work-bench so that the right side of the 7. Gold wax for clarinets lathe is at least 3’ from the vise at any point. 8. Flush bands This enables the mechanic to use the flat bed 9. Springs (needle and flat) of the lathe for alignment of trombone slides so 10. Post bushings and shims that they can be soldered together while lying 11. Kerosene, alcohol and thinner on the lathe bed extended from the end. 12. Norton Springs (Buescher) In this manner we can utilize the flat bed 13. Tone boosters of the lathe, thereby eliminating the Brown and 14. Pivot screws and rods Sharpe level, which is used to level trombone 15. Neck corks slides for mounting. In view of the fact that the slides would be extended from the bed of the Shop Layout lathe, no harm could come to the lathe. The shop should be set up so that the mechanic has the least trouble getting to the different tools thereby cutting down the amount of lost motion in the average work day. The vise is placed on the left side of the bench since it is easiest for the mechanic to work directly in front of his bench while an Shop layout with proper lighting. Small cabinets for materials such as clarinet, flute and piccolo pads can be placed on the bench at the furthest point from the mechanic. This is so placed since they are not in constant use. The same goes for the many small parts the average shop must have, such as pivot Reed instrument repair bench layout. screw springs, etc. Saxophone pad cabinets are kept at the ment available. It is advisable to consult your opposite end of the room to keep them clean. local equipment supplier or write the American The best effect in lighting is achieved by the Repair Service of Newark, N.J. for information use of a florescent fixture with two 40 Watt for your particular needs. tubes, placed approximately 8’ above the floor The lacquering booth should be stone and over the edge of the bench, running parallel to steel construction with its doors on springs that the bench. The same type lighting is recom- open outwards. The blower for the lacquering mended for the lathe; however, it is advisable booth should and must meet the underwriter’s to have a gooseneck light for fine work. The compressor should be placed under the bench so that the air pressure line can easily be brought to the top of the bench alongside the gas line so that the gas and air torch hoses can be secured together for easier handling. If the gas line has a double outlet the hose can remain permanently attached since the second gas outlet will take care of the Bunsen burner line. Best results are obtained when the bench is placed in front of a window. Polishing, lacquering and plating equipment should be in a different room that is well venti- lated because of the fumes from the plating Lacquering booth with ventilating fan. and polishing solutions. approval for insurance purposes. Polishing, Plating and Lacquering Shop The blower for the polishing lathe will depend Setup upon the size of the polishing lathe. The hopper for the blower should be placed The polishing lathe should be set at the fur- in the right hand corner of the polishing room. thest end of the shop near windows if possible. The bulbs used for lighting in the lacquer booth A polishing lathe for silver and gold plated should be encased in explosion proof contain- scratch brushing can be placed in the same ers. end of the room. There are dual speed lathes It is further advisable to use blower fans over for this purpose. all solutions to dissipate the fumes outside the The tanks can be set up on the left side of building. the room so that the rinsing tubs are between If a baking oven is used with the lacquering the acid baths. (See diagram). equipment it should be placed near the lac- The strip tank must have a gas line for quering booth. heating purposes as well as the regular hot tank for lacquer removal. The rinsing tank should be a double drain off bath so that clean rinse water can constantly be applied. Degreasing machines must be kept by a win- dow for ventilation. The lacquering equipment should be in a completely separate room to bring to a mini- mum the possibility of dirt and FIRES. Plating equipment should be kept as close as possible to the rinsing tanks in the polishing room. It is advisable to use stainless steel for all rinsing tanks. There are many types of lacquering equip- CHAPTER 2 BRASS INSTRUMENT REPAIR Dent Removal With Dent Rods ond method is used in those cases where the dent was caused by a sharp object putting Due to the fact that the position of each somewhat of a cut or nick in the metal. By ham- dent in a musical instrument presents its own mering in a light fashion directly on the cut, we particular problem. We shall have to describe may possibly close this cut sufficiently well, so the removal of them in separate categories. as not to be visible. Bear in mind the fact that There are three procedures to be used in the such hammering is done directly over the dent removal of dents that can be reached with a rod which is inserted in the slide bow. When dent rod. These three procedures are known as such a cut is removed, we merely use the pre- inside burnishing, hammering and the rebound ceding method to put the slide bow back to its method.
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