Here are some pictures of our first session from 4/4/06 during which we destrung the piano. As we removed the strings, we catalogued the string diameters so as to restring accurately.
(click on thumbnail for larger image):
On 4/11 we pulled the plate and set the piano up to dry for shimming. Below note the we set shims on the soundboard to dry out as well. We then covered the piano with moving blankets after setting out a bunch of heater bars under it and on the soundboard.
The pinblock is a floater, meaning it more or less fell out of the piano when we pulled the plate.
A close-up of the old block shows that it ruptured in the middle rendering it scrap wood.
4/18: Since we didn't have the tools available to shim the board today, we started working on the pinblock up upside down and punched out the old tuning pin bushings. The blue stuff is chaulk which suggests the pinblock we took out was not original.
We scribed the curve of the old block on the new stock:
During cutting we realized that the band saw needed some adjustment, so we spent some time trying to make it run better.
The old block was cut on too severe an angle and probably was not very stable.
At F&C's, they use DAG (an alcohol and graphite mixture) to fit the block. First, Bill applies it to the plate flange:
Then we push the block in and clamp it and rap it along the front with a rubber mallet to transfer the graphite to the high spots.
The high spots are then filed down and the process is repeated until graphite appears all along the block edge.
Bill, using a self-centering punch, makes drill marks on the block so we know where to drill when the block is removed for drilling
Although this pic is a little blurry, it shows the punch marks.
Then the plate is sprayed to look nice. We applied black magic marker to the raised letters. When they have a coat of clear lacquer, they look great!
Shimming the soundboard. First we used a soundboard shimming tool to cut a V-shaped groove for the shims. Then the shims are dry fitted.
When the shims are to be glued we clamped some scrap lumber across the top of the case to act as a brace for the turnbuckle clamps. A small piece of scrap wood sits atop the shim and is compressed into place by a turnbuckle which expands as the thread is turned.
After the shim glue has set, the shims, which stand slightly proud of the board, are planed so that they are flush with the surface. The soundboard is then sanded
The board is then finished and this is what it looks like with the plate -- all ready for stringing.
During action prep, Lee brought in his hammer filing contraption. It is created from an electric knife that has two opposing blades. The blades were removed, and the blade shafts spread to accommodate a strip of sandpaper (100 grit or so). The device makes for very clean, egg-shaped hammers with much less dust-throw than a dremel. The hammers are clamped tight beforehand to prevent ugly side-effects.
Meetings are typically at the Commack space (just northeast of the exit 53 LIE interchange) 4pm until 7pm weekdays. The address is 20 Austin Blvd which is right off of Motor Pky.