The Powell Handmade Alto

Powell's Repair Technician, Rachel Baker, has seen Powell flutes and piccolos of all ages and styles cross her bench over the years.  This week, however, she had the chance to work on something that she had never seen until now -- a Powell Handmade alto flute.

The flute (serial number 5006) was made in 1977 and was in the shop for a C.O.A. (clean, oil, adjust).  Looking back through the Powell Bible, we discovered that only 34 Powell alto flutes had been made in the history of the company.  The production of these flutes spanned from 1930 to 1990, with a large majority (15) being made between 1976 and 1978.  This particular alto was also one of only four that were made with gold lip plates.

Indeed, this was a special and memorable moment for Rachel. Speaking about the actual C.O.A. process on the alto, Rachel said it was pretty much the same as it is for C flutes.  She said, "same oil, same pads -- just things are a bit bigger." Although the flute originally had felt pads, we noticed that it now has Straubinger pads, so we could see her point about the similarity!

In terms of differences, this particular instrument was definitely one of a kind.  Rachel told us that when it comes to models (like altos) that were made in small quantities, you can find slight design differences among them.  She admired the keywork for its aesthetics and noted that both the body and mechanism were sterling silver.  She was particularly fond of the pointed arms and small points in the middle of the key cups which you will see in the photos below.

Although we did not have information on the actual karat of the lip plate, Rachel said that it is most likely 18k, as this was quite common during the time when this flute was made. Today, Powell offers alto flutes only in the Powell Sonaré line--the AF-60 and AF-70. Both models come with an all sterling silver Powell headjoint made at the shop in Maynard, Massachusetts, and a choice between straight or curved headjoints. Click here to find more information about these models on the Powell website.

Pad "Life"

Have you ever wondered how long flute pads last?  It may be surprising to some if pads need to be replaced during a COA, but try to think back...  How long have the pads been in there?  Have they reached their lifespan -- and what is the lifespan? 

We spoke with Powell Repair Technician, Rachel Baker, to find out just how long one should expect a pad to "live."  She told us that on average, it's about 5 years for flute pads, and anything older than 6 or 7 years should really be replaced.  Although there is no absolute guarantee for the lifespan of a pad, it is important to note that there are different "aging" factors in pads because of the difference in materials.  For instance, felt pads have a cardboard backing, and Straubinger pads have a plastic backing.  The plastic is more durable than the cardboard, so the Straubinger pads will last longer.  Also, moisture will affect felt pads in a much greater way because felt pads are comprised of more "organic" materials.  Rachel tells us moisture causes the felt and cardboard in a felt pad to shrink -- and it is also what causes them to smell "moldy" over time.

Using the feeler gauge after repadding.

However, there is one crucial "sign of aging" with pads that certainly determines when they need to be replaced -- resonance.  Loss of resonance means it is time to replace the pad, and this is particularly true with Straubinger pads, which Rachel says, "are known for their crispness and resonance."  She tells us that she had many customers who had pads replaced during a COA or overhaul and noted how much better their flutes played.

As for piccolo pads, they don't wear out as often as flute pads.  Why is this?  Well, Rachel tell us that there are two main reasons: (1) piccolos are usually not played as much a flutes, and (2) piccolos have wooden tone holes that are softer than metal tone holes.  She says piccolos also have some cork pads which will definitely last longer because they are made to handle moisture better.

As we can see, pads will not last forever, but they do have a decent lifespan.  They can also make a world of difference to your flute.  So if you get your flute back from repair, and your technician says s/he replaced some pads, see if you can tell the difference!

Felt or Straubinger?

Left to right: Straubinger, hard pressed felt, soft woven felt

Many flutists will send their instruments off to the repair shop and learn they need to have their pads replaced.  At that point, the repair technician may ask, "Which would you prefer -- felt or Straubinger?"  Hmm...  So, how do you choose?  Well, we spoke with Powell's Repair Technician, Rachel Baker, to find out more about the pads and get her recommendations...

A quick review of the pads with Rachel helped us recall the difference in materials:

Felt pads - cardboard backing, pressed felt, skin (bladder skin covering)
Straubinger pads - plastic backing, microfiber, skin (bladder skin covering)

Rachel told us that the pads each have different characteristics based on their composition.  In terms of feel, the materials create a noticeable difference because the pads will hit the cups differently when you play.  The felt has more give and can handle extra upward pressure (exerted on the pad when you close the key cup), so she said they tend to be better for people with "heavier" hands.  The Straubinger pads have a crisper response than the felt, so someone with a lighter touch may prefer these.  The Straubinger pads also tend to have more stability because they are made from synthetic materials.  The natural materials in the felt pads fluctuate more with changes in atmospheric conditions, so, for instance, a flutist living in a very humid climate would probably not have as much luck with the felt pads because of the humidity.  In terms of sound, one might not realize, but there is a difference.  Rachel said that one pad is not better than the other -- it just all depends on the player's sound preferences. If you think about the physics behind sound production on the flute, as air travels through the instrument, there will be a difference in sound because of the difference in materials (felt or synthetic pads) closing the tone holes.  Sound discrepancies may be difficult to describe, but some players may note general color/quality differences such as a "brighter" or "darker" sound, depending on their choice of pads.

Signature flute with Straubinger pads in for a COA.

When speaking with customers, Rachel said that she asks several questions to determine what type of pad might be best for them.  First, she asks what type of pads are currently on the flute.  Many flutists may not know which type of pads they have, but that is okay.  Rachel will continue with more questions about the type of playing the flutist does, where they live, what type of sound they prefer, and any issues they may be having with the flute.  For instance, we noted in the previous paragraph that someone living in a humid climate might have problems with felt.  When it comes to type of playing, she asks, "Do you play outdoors or indoors?   Marching band?  Concert band or orchestra?" Then, she asks about their preferences and any issues, "Is the sound too bright?  Too dark?  Not projecting enough?"  These questions help her get a sense of the flutist's preferences and also help paint a picture of the performance environment the flute will have with each customer.

Powell Sonaré Repair

Powell Sonaré 505BOF

When we stop in to see our repair technician, we usually see the whole range of Powell models -- Signature, Conservatory, Custom.  However, Powell Sonaré flutes rarely come in to the shop here.  Why is this?  Well, Powell Sonaré flutes are mostly serviced by repair technicians at the dealer location where the customer purchased the flute or by other local repair technicians in the customer's area.  There are numerous dealers across the country who sell and service Powell Sonaré flutes and many independent technicians.  For Powell models, there are fewer dealers in comparison.  Each Powell dealer must have a Straubinger-certified repair technician since Powell models use Straubinger pads.  Since there may not be a Powell dealer close to every customer, or Starubinger-certified independent technician, many customers send their flutes directly to Powell for repair.

Although Powell's repair tech, Rachel Baker, doesn't see many Powell Sonaré flutes on a regular basis, we were still curious about differences in repair between Powell and Powell Sonaré models.  She told us that essentially, the repairs she does are pretty much the same -- replacing pads and adjusting the mechanism.  These are the essentials which she does on all flutes.  The only difference, she tells us, is time.  She says that the time it takes to repair a Powell Sonaré is less than it would take on a Powell.  Why is this?  Well, there are a couple of differences.  The Powell Sonaré models have felt pads and a different mechanism.  Specifically, the tolerances on the Powell Sonaré and Powell models are different, and this is what accounts for the difference in repair time.  You may notice tolerance levels in the "feel" of the mechanism.  Since Powell Sonaré flutes are designed for younger players, the tolerance levels do not need to be as high as they would on the Powell models. Mechanisms with very high tolerance levels will take much longer to adjust.

You will find a complete list of Powell and Powell Sonaré dealers on the Powell website at https://powellflutes.com/dealer.  Powell repairs may be scheduled directly through the website at https://powellflutes.com/repair-doctor/schedule?destination=repair-doctor/schedule/repair.

Powell Sonaré 505BOF (far left) and other Powell models in the testing room

Repair or Replace: Pads

We thought it might be interesting to look at a few components of the flute over a series of posts and examine whether they get repaired or replaced when a flute is sent to the repair shop.  Of course, we stopped in to see Powell's Repair Technician, Rachel Baker, to help us begin this series.  We wanted to start with pads, so we asked, "When a flute comes in, do you repair or replace the pads?"

Well, in the case of pads it's an either/or situation.  Pads can be "repaired" or replaced.  What would constitute a pad "repair?"  Shimming!  Rachel says that the type of repair most commonly done with pads is shimming.  Shimming is done to correct leaking pads.  When it comes to replacing pads, there could be a couple of things that would lead to this solution.  Obviously, if a pad is torn, it needs to be replaced.  Also, like anything else, pads age over time.  As they age, the skin on the pad can get brittle, and the pad would need to be replaced.  Brittle skin is more likely to tear, which (as we know) is certainly cause for pad replacement!

When it comes to pads, a "matching set" is very important as well.  Felt pads and Straubinger pads have different compression rates, so it is important to make sure that all the pads are the same type (or rather, "match") on the flute.  You don't want to mix the pads and have a few felt here and there and then a few Straubinger.  Definitely not a good thing.  If a flute comes across Rachel's bench and has "unmatched pads," well, some of the pads would need to be replaced.

So, in the case of pads, they may need to be repaired, or they may need to be replaced.  Visual inspections, play tests, and checks with the feeler gauge can all help determine whether the pad should be "repaired" or replaced.

This pad's edge has been "lifted up" and definitely needed to be replaced.

This flute has matching pads and is good to go!

Flute Pad Choices

Did you know that when you send your flute in for repair at Powell, you have a choice of pads?  There are three types of pads to choose from since today's flute pads may be different from older models.  Current Powell models are outfitted with Straubinger pads, which Powell started using around 1990.  Other pad options are hard pressed felt and soft woven felt.  Construction layers differ in these pads and are described below:

1) Straubinger pad - Plastic base, thin microfiber layer, skin
2) Hard pressed felt pad - Cardboard base, thin pressed felt, skin
3) Soft woven felt pad - Cardboard base, thicker woven felt, skin

L to R: Straubinger, hard pressed felt, soft woven felt

So, which should you choose?  It is really a matter of preference, but our website mentions the following characteristics:
 
*Felt pads: Made of cardboard, felt, and a bladderskin exterior. Softer, not as resonant, but can withstand significant finger pressure.

*Straubinger: Made of plastic, microfiber, and a skin. These are used on all of our new flutes because they are designed to be more stable and resonant. In addition, they give the mechanism a crisp response.

Whichever works best for you and meets your needs as a performer is really the best choice!