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Flute and Piccolo Repair

Flute Repad and Mechanical Overhaul

Flute Repad

Flute is disassembled and cleaned, and dents are removed. Keys are leveled, straightened, and swedged, removing play and wobble, and refit between the posts. All pads are replaced. Key corks, head joint corks, felts and springs are replaced as necessary. Instrument is reassembled, lubricated, regulated, adjusted and thoroughly play tested. Prices below. Flute will play as good or better than new.

Flute Mechanical Overhaul

Same as repad except head joint cork and all key corks are replaced and the flute keys and body are buffed (student and intermediate) or polished (pro). Flute will look like new (as much as possible) and will play as good or better than new.

Straubinger Mechanical Overhaul

Same as mechanical overhaul except Straubinger pads are used. Pro flutes only. Flute will look like new (as much as possible) and will play as good or better than new.

Flute Complete Overhaul

Same process as the mechanical overhaul but also includes the stripping of plating and replating. Call or email for prices and turn-around time. Flute will look like new and will play as good or better than new.

Typical turn around time for repads and mechanical overhauls is 2 weeks (plus shipping an approval time if necessary).

Flute Repad and Overhaul Pricing

Repad/Mechanical Overhaul Student
Intermediate
Intermediate & Pro
(Mass produced)
Pro
(Handmade)
Repad - closed hole $255 $295 $675
Repad - open hole N/A $345 $775
Mechanical Overhaul - closed hole $295 $345 $825
Mechanical Overhaul - open hole N/A $395 $925

Piccolo Repad and Overhaul Pricing

Repad/Mechanical Overhaul Student
Intermediate
Intermediate & Pro
(Mass produced)
Pro
(Handmade)
Repad $255 $295 $725
Mechanical Overhaul $295 $345 $775

 

 

Items not listed in above overhaul process that will incur extra charges:

Flute Repad and Mechanical Overhaul Process

1. Straighten body: The flute is really nothing more than a thin tube of metal with holes in it along the length of the tube. At a couple areas on the body there are two tone holes positioned relatively close together (at thumb B and Bb keys and G and G# keys), weakening the tube even more. It doesn't take much to put a slight curve into the body with a little careless handling. One brand, because of the manufacturing process, even comes from the factory already bent!

Because a bent body affects every mechanical aspect of the flute, the body is straightened (if necessary) before any other work is done.

2. Remove dents: Next, dents are removed using a straight mandrel for the body and a tapered mandrel for the head joint.

Flute dent removal

3. Fit tenon: The foot joint tenon and receiver are fit to an air-tight metal to metal seal using a combination of tools and lapping for final fit.

Head joint in tenon shrinker

If is common for the foot joint tenon to be slightly bent causing the foot joint to angle slightly to one side. If this is the case, the tenon will also be straightened during the fitting process.

4. Disassemble flute: The flute is disassembled, fitting the keys to rods and between the posts. The worn hinge tubes of the keys must be swedged back down to fit the rod, or, if the posts are also worn, oversized hinge rods must be fabricated to fit the post and the keys refit to the new rods. Hinge tube ends are faced and deburred. Key sections are fit between pivot screws.

Swedging hinge tube Facing a hinge tube Disassembled flute

5. Remove pads and corks: The old pads and corks are removed from the keys.

Flute pad removal

6. Facing and shaping tone holes: Tone holes are faced removing nicks and scratches and making the tone hole as level as possible without compromising the chimney. Tone holes of pro level flutes also go through a shaping process.

Leveling flute tone hole

7. Buff or polish: Keys and body are buffed (student and intermediate level flutes) or hand polished (pro flutes) on mechanical overhauls. The bore is also polished on pro level flutes.

8. Clean: The flute is cleaned using either ultrasonics or a series of brushes with a cleaning solution, or both, depending on the condition of the flute.

9. Clean posts, rods, and hinge tubes: All key groups are disassembles (left hand stack, right hand stack, and trill keys). Posts and hinge tubes are cleaned with pipe cleaners and a degreasing solution. Rods are straightened and key sections are re-oiled and reassembled.

Cleaning flute hinge tube Key group disassembled

Old oil and gunk are also removed from the rods with the same solution.

10. Install corks and pads: The key bumpers are replaced using cork on student flutes and felt of pro flutes.

11. Assemble: Student Flute - One key section at a time, the flute is assembled, leveling keys/pads over tone holes. After each section is leveled, it is removed and set aside. After all keys have been leveled, the flute is given a final light polish to remove finger prints and the instrument is oiled and assembled.Pads will seal with little pressure. Rough adjustments are made.

Leveling flute key cup Checking pad seal

12. Light clamp: Open keys of student flutes are lightly clamped for a very light impression and the instrument is left to sit for a couple of hours to overnight. It is then unclamped and left to sit for several days to a week. Pro flutes do not get clamped.

flute clamps

13. Adjust and regulate: The instument is gone over again to remove any pinhole leaks that have occured due to the settling of the pad felts. Final adjustments and regulations are made.

14. Play testing: The flute is thoroughly play tested.

15. Final: Horn is wiped off, the case is vacuumed, and the customer is informed of the completed repair.

The Fine Print

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