Greetings, I've been using Spurlock's cauls for rebushing keys with great success. I use the mortising cauls when removing the old felt, which leaves the slots smooth and uniform. Then I use the two step- intermediate and final- cauls for gluing (hot hide glue, of course) in the new cloth. I've done several sets this way and always had very little easing to do when installing the keys. They've been near perfect- until this last set. This last set, a Schafer and Sons (read Samick) upright, about 20 yrs old, the front rail pins are all a little snug, not too bad, but they all needed a little easing. But the balance rail was all too loose, really unacceptably loose. We used the same mortising cauls, the same intermediate and final cauls, the same bushing cloth. The only difference was my son-in-law took out the balance rail bushings and I took at the front rail bushings. Our method is to turn up the heat on the glue pot so the water is bubbling boiling and hold the key over the steam for a few seconds. The old cloth practically falls out. He may get it a little moister than me, or vice versa. On this particular set, he removed the old balance rail cloth about 2 weeks before the new was glued in. I removed the front rail cloth about a week before the new was glued in. My son-in-law put the new cloth in both balance rail and front rail, so there would be no difference in method there. Anybody have any thoughts on what happened? How long would you wait between removing the old cloth and gluing in the new cloth? I.e., how much drying time would you give the mortises? BTW, using this steam method to remove the balance rail felt actually "sizes" the worn balance rail hole, closing it up a tad. This allows you to ease it back up to the perfect size when installing. I use the Yamaha capstan wrench: a very gradual taper that allows very uniform results. Dean Dean May cell 812.239.3359 PianoRebuilders.com 812.235.5272 Terre Haute IN 47802
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