David S (hold the c, no mayo) said <Would I assume that if the key frame used .162" pins, or other, you would modify the jig accordingly? It could be a replaceable pin, or just a 2nd set since its all so simple. For my own shop use, I would go for making a second .162 set, as replaceable anythings escalates the complexity of the jig. I swear though...after making jigs for 25 years, except in rare production circumstances, I go for single purpose, rot gut simplicity in the construction and definition of purpose. Time and time again I've watched great efficient jig ideas turn into unmanageable monsters when trying to make them multi-purpose. <Also, is it correct that you are keying off of the original balance hole? Yes <If so, and 'ovaling' has taken place, how do you accommodate? Have you used this system to do an entire set? The maiden voyage was on the maple clickety-clackety shoes, so although it was a full keyset, the existing balance holes were 4 yrs old, trustworthy and round. Final alignment was excellent. As well, the pin indexes were in hardwood not soft key stick wood, so they went together with literally no slop. For sure, the ovaling problem will have to be dealt with on any worn out original balance hole, and any hole replacement procedure needs to account for this. However, in this project I didn't need to work that problem because the holes were trustworthy. One of the things I really liked about how this worked was that once the jig was made, all of the processes on the key actually preferred the use of a hand drill. I used one of those straight driver/drill items, and the drill bushing combined with straight driver/drill, which was held loosely, easily found the bits center of rotation. I tried a couple on the drill press, and the drill press was not an improvement. If only those little driver drills ran at a higher rpm they would be just the dandiest. Will's punching idea sounds good. Some favor the front of the hole on placing the new hole, I think, on the theory that the back of the hole takes the beating. But this introduces slop, which starts the whole thing down the guessing game route. Other than Will's idea, which sounds doable, I'll have to chew on this. Other ideas out there? Jim Ialeggio -- Jim Ialeggio jim at grandpianosolutions.com (978) 425-9026 Shirley, MA
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