Conover Plate cracks

[Richard Snelson]

I would like suggestions and ideas on how to repair the following:And
your thoughts on how I'm currently going about it.  
Piano: Conover 1908 6' Grand. The piano had four individual pin blocks
seperated by three webs in the plate. The pins blocks are open on top
with no web covering. On the bottom they are tied together by a single
maple 1/2" thick cap that holds the whole pin block together. The two
1/4" thick webs in the treble section are cracked one completely from
top to bottom and the other half way up. Piano case is beautiful walnut,
sound board is in good condition, action in fair condition.  

Looking carefully at the tiny amount of evidence available, it seemes
the piano was repaired for this problem in 1928 at the Cable Factory in
Chicago (Signed/dated by the worker on a string support wooden piece).
This is based on the weld flanges used to repair the webbs and the cuts
made at that time in the seperate pins blocks that had been out of the
piano. The cracks were not showing when I obtained the piano but did
after I removed the plate. I understand the welds failing because of the
hardness of the cast iron on each side of the weld. Sloppy work on my
part, in lifting the plate at the back edge with out support on the
front edge which was stuck, no doubt cracked the welds loose.

The web starts in the vertical direction 1" below the pin blocks top
surfaces and extend about 1 1/2" above the pin block. The part at the
very bottom edge that had been welded was  narrow 1/8" and this is where
the crack had started.  I think this is a basic design flaw in the
casting. 

I have repaired one crack with Lock-n-Stitch and will do the other
partially cracked webb next. I don't have a lot of faith in the
Lock-N-Stitch. I will address this to the list if there is interest in
how to complete a Lock-N-Stitch repair. It can be tricky! I have cut the
1" webb that extends between the pin blocks off completely and have
designed a 1/4" steel truss to go in it's place. It will be bolts to
each side of the area, front/back with aircraft bolts. 

I understand the thinking of those that will say "junk it now." You are
no doubt correct. However, I need a project for my own education. I'm
thinking of completing the plate repair. (With your inputs to help) 
Spray painting the plate/making new pin blocks. Installing the plate,
stringing the piano and bringing it to pitch. If it's OK at that point I
would leave it for a while before lowering the pitch, and again removing
the plate to do all the refinishing on the sound board/case etc. I don't
see a problem with removing the plate with the srings in place, I'm the
new kid on the block at this, so is this correct??  

Some of my Questions: What do you think the load is on the webs?
Are they in tension? 
Small to almost no load? 
Anyone had luck with brazing cast iron? 



Oh by the way, I would keep the piano for myself and not pass it off to
some unsuspecting customer. My wife loves the ornate walnut case. 

Richard Snelson 
Clinton, IL 
Phone: 217-362-7432 days   217-935-4215 eve.