Piccolo Overhaul

This week, our repair technician, Rachel Baker, was working on a piccolo overhaul when we stopped by to see her. Specifically, she was working on overhauling a Custom kingwood piccolo with silver keys.  Hmm.... Piccolo overhaul? We were very curious, and (of course) we wanted to find out more, so we asked!

Rachel says piccolos are usually overhauled much less frequently than flutes because (in comparison) they are played less.  It can be several years between overhauls for a piccolo. The overhaul includes changing all the pads, bumpers, and key adjustments.  She also oils the mechanism and replaces the tenon cork.

Another important part of the piccolo overhaul is the oiling of the body and headjoint.  Rachel oils both the bore and the outside of the piccolo.  This is best left to a professional, but Rachel tells us that it is okay for piccolo owners to oil the area of the headjoint around the embouchure since it gets so much wear.  You'll want to be very careful if you oil this area, and Rachel recommends pure pressed almond oil.  She says that if a little bit gets in the embouchure hole, you can simply wipe carefully around the edge with a Q-tip.

The Repair Warranty

When you purchase a new Powell flute or piccolo, the instrument comes with a one-year warranty (which you can read about by following this link to our previous post on the warranty).  In addition to this warranty, repair work is covered under a warranty as well, as you will see below:

C.O.A.s are covered by a 30 day warranty and overhauls are covered by a 90 day warranty. If your flute is overhauled with Straubinger pads, pad seating is covered under the warranty; with felt pads, seating is not covered. The warranty is void if anyone other than Powell (unless approved in advance) works on the instrument during this period.

Much like the instrument warranty, if someone other than Powell works on your instrument during the repair warranty period, this warranty may be voided.  This is because it would not be possible for our repair department to evaluate and assess our original repair work if additional work is done afterwards by someone else.  So, if you have questions about your instrument after receiving it back from repair at Powell, make sure to call our repair department right away.  The work is covered under warranty, and our repair technician will be happy to help!

The Overhaul

Powell Repair Technician Rachel Baker working on an overhaul.

In a previous post here on Repair My Flute, we covered the topic of how one determines whether their flute needs a COA or an overhaul.  You can read that post by following this link.

If it is time for an overhaul, you may have wondered what exact steps are involved in the process.  We have the answer from the repair page of the Powell website as you will see below...

The Overhaul involves the complete disassembly and reconditioning of an instrument. The time between overhauls is dependent on many factors, including climate and the quality and frequency of C.O.A.’s. A rough average would be three to five years. For a normal overhaul the labor charge is $1000.00 for flutes and $725.00 for piccolos, and the only parts cost is a set of pads. Expect to be without your flute for four weeks or piccolo for three weeks while it is being overhauled. Overhauls are warranted for 90 days.

1. The instrument is play tested and checked for all mechanical and structural work that will be required. The client will be contacted if the required work exceeds the authorized limit, and the charges will be discussed.

2. All pinned sections are taken apart; pads are removed and thrown away.
 
3. Corks, felts, foams and headjoint cork are removed and thrown away.

4. The flute is cleaned in an ultrasonic bath to remove dirt, oil and grease. The flute body and keys are then dipped in a tarnish remover.

5. Swedging, replacement of worn pins, and key fitting, as well as required mechanical and bodywork are done, as per findings in #1 above.

6. The precious metal parts are shined and treated with silver polish.

7. Pads are installed.

8. Corks, felts and foams are attached. The headjoint cork assembly is polished and a new headjoint cork is installed.

9. The keys are oiled and assembled.

10. During the final padding process the instrument is played frequently so that pads can settle. Adjustments are made.

11. The instrument is play tested.

12. The instrument case is cleaned and polished, then shimmed (if necessary) so that the instrument fits snugly.

Exclusions: The removal of scratches, nicks and dents is done only at the client’s request, and is charged by the hour. A bearing job may be required if the right and left hand sections exhibit side play in the F# post at the cost of $213.00. Re-soldering of un-soldered tone holes is charged by the hour.

You may schedule an overhaul directly through the Powell website. Click here to visit the repair scheduling link.

Time for a COA or Overhaul?

Flutes in the repair shop for COAs and overhauls.

We all want to protect the health of our flutes with good care and maintenance, but how do you know when it's time for a COA or overhaul?  We checked with Powell's Repair Technician, Rachel Baker, to find out!

Rachel tells us that it depends on how much playing you do, but if you play regularly, you should get a COA every year.  If playing flute is more of a recreational activity rather than something regular, you can have a COA done every other year.  No matter the case, she advises that the maximum amount of time between COAs should be no more than every other year.  Sending your flute in for a COA is a terrific preventative measure, too, because it will help catch things that degrade over time and fix them.  For instance, pads will wear over time and need to be replaced.  With a regular COA, a pad or two may need to be changed every year.  However, without regular maintenance, you may find yourself in a situation with, say, five pads needing to be replaced -- and at that point, you would need an overhaul.  The COA will also help correct the normal wear of the mechanism.

So, how do you know when it's time for an overhaul?  Rachel says that the mechanism is really the indicator.  As mentioned above, it does wear over time, and even with regular COAs your flute keys will move laterally more than they should, and the mechanism can get "clanky" or "noisy."  When this happens, it's time for an overhaul.  Also, make sure to check the condition of your pads.  When they become warn, they can lose resonance.  This wearing can happen in two ways: (1) from regular use, and (2) from pads drying out and becoming brittle, as one would see in a flute that has been left in its case over time without being played.

Finally, Rachel mentioned that many flutists will lose confidence in their playing and feel like they are doing something wrong if their flute is "playing less well" than it used to, when it actuality, the flute may simply need an overhaul.  As always, if you feel something just isn't right with your flute, make sure to contact your authorized repair technician.  Now that we are getting into the summer, it may be the perfect time for that overhaul or COA.  Just a reminder that it's quick and simple to schedule your repair online on the Powell website.  Click here to follow the link to the online repair request form.

The Appraisal

Flutes in for overhauls at the Powell repair office

We recently had a customer in the shop who wanted to get his Powell appraised, and the flute was quite old.  He was interested in selling it and wanted to get an idea of its approximate value (for resale).  Unfortunately, we are only able to give appraisals for insurance purposes.  This type of appraisal is based on a flute's specs and gives the flute's value so that the insurance company would know how much it would cost to replace the flute with one that is brand new -- in the event that the flute being insured is lost, stolen, or damaged to the point of needing to be replaced.

Appraisals for resale value are quite different than insurance appraisals.  The resale value is based on factors including the demand of the instrument, pitch, options, and condition of the instrument (pads, mechanism, and body).  So, we asked Powell's Repair Technician, Rachel Baker, her thoughts on overhauls for flutes that were ultimately going to be sold by their owner.  Our questions and her answers are below:

Questions: If a flute is in need of an overhaul, should the person do it before selling the flute?  If they go ahead with an overhaul, how will it help?  If they don't, what is the downside?

Rachel's Answers: It can go both ways. IF the flute is playable in its current condition, I usually recommend NOT doing an overhaul. This way the buyer can decide what type of pads, and who does the overhaul.

The downside of that is you will have to drop the price to factor in the price of an overhaul for the buyer. Also, they might not get the full sound of the instrument if it is in only mediocre playing condition, and this could make it harder to sell. 

So, there you have it -- a bit of an "chicken and egg" situation in terms of the overhaul question, but it certainly does make sense to wait on the overhaul and let the new owner have has his/her choices for materials and repair techs.

Note to Repair Tech

When you send your flute out for a COA or overhaul, your repair technician will certainly know what to do in terms of standard "procedures."  However, our repair technician asks customers to answer a few questions before sending their flutes in to the shop -- just to give her a general idea of their preferences.  In other words, she likes to know how the customer prefers a few things like fit and tension so that she can make the flute feel exactly the way they like it when it's done!

So, if your technician does not already ask, you should still share your answers to the following questions when you send your flute in for standard maintenance:

1) Are there any problems with the flute?  This would include anything happening with your flute that is not "normal."  You may have trouble getting certain notes out, or you may notice that some keys are harder to close than others.  Perhaps you have some sort of key noise or sticky pads.  The list could go on and on, but you probably get the point!  Let your technician know about any issues you might be having with the instrument.

2) How do you feel your headjoint and footjoint are fitting?  If your headjoint and footjoint are not fitting the way you would like them to, let your technician know.  Perhaps they are too loose or too tight.  Fit issues can certainly be remedied by the repair tech.  It's important to let the tech know, because flute players have different preferences when it comes to headjoint and footjoint fit.

3) How do you like the current spring tension on your flute?  Again, players have different preferences here.  Some players prefer a lot of tension, some not so much.  You can certainly feel the spring tension in your keys when you play.  If you think you would like more, less, or the same, let your technician know.

The technician will normally gauge tension and fit against his/her standards, so even if tension and fit do not need to be adjusted, make sure to indicate this.  Your tech will get a sense of how you like the flute to feel.  When the tech first receives the flute, s/he will evaluate it -- and your answers to the questions above will help in the assessment.  Once your tech knows your preferences, s/he can make sure your flute has the perfect feel when you receive it back from repair!

Mechanism Wear

We recently had an artist ask our repair technician if a mechanism can "wear out."  We thought that was an excellent question, so we decided to find out more...

Our technician, Rachel Baker, told us that a mechanism doesn't "wear out," but it does "wear" over time.  The mechanism tubes are constantly rotating on the posts and the inner steels, which causes the mechanism to wear.  Specifically, as the mechanism becomes worn, it becomes somewhat loose.  This loosening creates extra side-to-side and radial "play" in the mechanism.  The side-to-side play comes from the mechanism tubing moving against the the post, and the radial play comes from the movement of the mechanism tubing against the inner steel.  You can read more about "play" in a previous post here at http://www.repairmyflute.com/2012/08/play-in-mechanism.html.

As the mechanism wears, a couple of issues arise -- noisy keys, unstable adjustments, and unstable pad seating.  All of these problems can easily be solved by the repair technician.  In fact, worn mechanisms are always adjusted when a flute is sent to Powell for an ovehaul.  During an overhaul, the mechanism will be tightened and the keys fitted to restore proper function.

When do flute mechanisms begin to wear?  Well, it all depends on the amount of usage over time.  If a flute is twenty years old, but has been sitting in a closet untouched, there may be very little wear on the instrument's mechanism.  If you have a new flute and practice regularly for several hours each day, the mechanism may become worn faster.  The more use a flute gets, the more it will wear -- just like many things (tires, shoes, and the list goes on...).  There is no need to worry, though.  It is all part of the instrument's life cycle.  Plus, as mentioned above, a worn flute mechanism can be easily adjusted by an authorized repair technician.

Flute on the far left was made in the 1940s and has its original mechanism, which has just been adjust in an overhaul.  Two flutes to the right are Conservatories, which were both made after 2002.

Close-up on the body mechanisms of the three flutes.

Close-up on the footjoint mechanisms.

Felt and Foam

In our series of "repair or replace" topics, we thought it would be interesting to look at "tail felts and tail foam."  These are found on the "tails" of the keys where the tail hits the body of the flute.  The purpose of these felts and foam is to control key height and stop noise (from the mechanism).  Some flutes have all foam tails, some have all felt, and some have both.  It really just depends on the flute.

So, we asked our repair technician if these are repaired or replaced.  We had an inkling that they would be replaced, because it isn't really possible to "repair" such a small piece of foam or felt.  Indeed, they are always replaced.  When?  Well, they are replaced when you send your flute in for a complete overhaul.  Why is this?  It's because in an overhaul, the keys need to be removed from the flute so that they can be polished on a buffing wheel.  Since the entire key (including the tail) gets polished, the felts and foam are removed.  Then, they are replaced in the process of putting the keys back on the flute!  In general, the felts and foam are left in tact during the light polishing during a COA.  However, a felt or foam tail can always be replaced if necessary from wear.

Finisher adding felt to keys.  Yellow arrow points to finished felt on key.

Orange arrow points to foam on key.

Red arrows point to foam, yellow arrows point to felt.

Repair on the Road

Repair Technician Rachel Baker (far right) at 2012 NFA Convention

We've been busy getting ready for the NFA Convention, so we thought it would be a great time to stop in and chat with Powell's Repair Technician, Rachel Baker, to ask about her role in the show.  Rachel attends with a group of Powell's sales and marketing team and works at the booth, speaking with customers, showing flutes, and...

Repairing flutes?  How would this be possible off site?  Does she repair the flutes at the booth throughout the show?  We wondered about all these questions, so we thought we would ask her.  Essentially, when it comes to repair at the NFA, there are two areas she addresses -- customer repairs and booth inventory.

When it comes to customers, Rachel often times gets requests to do repairs at the show.  People are there from all over the country, so it seems like a good time/place for repair.  However, since Rachel is out of her shop at Powell, her repair resources are limited.  Her basic rule of thumb when it comes to what is possible at a show is "anything within reason -- nothing drastic."  So, with a limited "travel toolbox," Rachel is able to make a couple of adjustments to flutes.  She can replace a pad, fix one major adjustment issue, adjust loose springs and spring tension.  She could also replace a missing key tail cork or tail felt.  Essentially, she can do "little bits" that would be part of a COA, but definitely not a complete COA or overhaul.  She also brings a mandrel and burnisher to fit headjoints.  So, if a customer buys a new headjoint and needs to have it fit, that is possible.  She can also fix any headjoint fitting issues with their current flute and headjoint.  Rachel brings a couple of headjoint corks as well, so if someone needs theirs replaced, that can be done!

So, the show goes on for several days, and the flutes and piccolos are played again and again...  Does Rachel get bogged down making adjustments to these?  The answer to this question is no.  As Rachel says, "That's why I spend so much time before the convention getting everything ready -- so I can pay attention to customers as opposed to instruments."  That certainly made us smile!  She says that sometimes, people will come to the booth and want her to take a look at their flute to see if it needs an overhaul or repair.  But, in general, her time is devoted to any customer visiting the booth.  She truly does spend an incredible amount of time prepping the inventory so that it is adjusted, ready to go, and (most importantly) securely set to function properly and without any issues throughout the show.  We thank Rachel for her meticulous and diligent work.  If you are coming to the convention to try Powell flutes at the booth, rest assured that they are ready for you!

The flutes are in tip-top shape so that Rachel can attend to customers!

Pre-Loved Powells

We recently stopped by the repair shop to check in with Rachel, our Repair Tech, who was busy working on a few overhauls.  It was interesting to see some examples of the "before and after" of overhauling "pre-owned" Powell flutes -- or what she fondly refers to as "pre-loved Powells."  Rachel holds the pre-loved Powells in the highest regard.  She has seen so many come through the shop, and even in the most trying states of condition, she is able not only to restore them but also to appreciate that there is much more to the overhaul than just mechanics...

2100 awaiting an overhaul

After Rachel notified one of the customers that his flute had arrived safely, she received the following e-mail:

Hello Rachel,

Thank you for the update. I'm looking forward to having the Powell fully restored. Take good care of it. Life has asked little from it, but given it lots of abuse.

Rachel receives many communications from people looking to buy and sell older flutes.  Of course, we are always very happy to help our customers pinpoint the exact new Powell of their choice, build it, and then ship it to them -- completely untouched.  So, why would one consider a pre-loved Powell? There could be a couple of reasons. Rachel mentioned that a pre-loved instrument could make a good, quality back-up flute. She says, "People may be hesitant to look at an older instrument because they think it may have problems.  Plus, everyone likes new, shiny things...  But, everything can be fixed and repaired on a flute -- and made shiny again!" She added that you can also try these pre-loved Powells to see if you like them.

Looking beyond the outside of an older Powell, Rachel shared with us a few more reasons that you might consider these pre-loved flutes. Recalling the exact words of the e-mail above, she expanded on the sentiment: "They each have a different character about them.  Plus, if you think about it, you realize that you are giving them a chance to have a new life, and that's what they were meant to do.  They were meant to be played, not left in a closet all alone.  If you choose one, you can help it fulfill its purpose in life."

So, if you discover an older instrument that looks a bit faded and worn, rest assured that it can begin a new life with a little help from your repair technician...

Might not look very shiny -- yet.

Certainly different looking than something brand new.

Has seen some wear, but...

It can begin a new life after an overhaul!

The overhauled 2100 on the left, a Conservatory in for a COA on the right.

Looks pretty shiny now!

Very shiny!

Getting a Grip on Key Pads

A Powell flute has Straubinger pads, which for most keys are held in place by screws or bushings.  But, alas, there are some pads on a Powell that are held in place by shellac.  We visited the repair shop when Rachel Baker was just about to seat or "float" some pads into place.  Specifically, the C1 and trill keys on a Powell are held in the key cups by shellac.  It seems like it would be pretty straightforward, but we realized there was much more to it than we thought.  Rachel told us that the shellac needs something to grab onto, so the inside of the key cup and back of the pad need to be "scored."  Scoring is a process that makes the surfaces a bit more "rough" so the shallac can grip these surfaces. If the pad and key cup are not scored, the pad could fall out easily over time.

To score the pads, Rachel takes a tool with a sharp, needle-type tip and pokes holes in the back of the pad.  She does this whenever she replaces the pads held by shellac (C1 and trill as mentioned above).  The pads on these particular keys are replaced on a C.O.A. if necessary and always replaced during an overhaul.  She also checks to see if the inside of the key cup has been scored.  If not, she takes a scraper and scores the inside of the cup by making a few lines in the metal.  The shellac is then heated, and the pad is "floated" into place.  With the back of the pad and inside of the cup scored, the shellac now has something to grab onto, and the pad should stay securely in place!

About to score back of pad with the needle-tip tool.

Poking very small holes to score back of pad.

Scraper is used to score the inside of the key cup.

Making lines in the cup to score it.

Scored key cup and pad.

Heating shellac with an alcohol lamp.  Heated shellac will then be applied to pad to "float" it into place in the key cup.

Key Engraving

Have you been thinking about having the keys on your flute engraved?  If so, you might be wondering how much that would cost -- and when the best time to do this would be.  We recently caught up with Rachel Baker, our Powell Repair Technician, to discuss this topic.

Rachel sees many flutes cross her bench for overhauls.  She said that sending in your flute for an overhaul would be the perfect time to have keys engraved.  During the overhaul, "everything is apart," so the keys are off the flute and easily accessible individually.  She also told us that key engraving is perfectly safe -- it only involves the surface of the keys, so the keys would not be damaged in any way.  Why would one choose the engraving option?  Well, in addition to aesthetics, Rachel told us that sometimes it's helpful for flute players whose fingers tend to slip on the keys.

We've featured photos of one of our engraver's work here in this post.  He has a standard set of patterns, although Rachel says it might be possible to have a custom design if you have something special in mind.  Our engraver is flexible!  How much would this cost?  Well, engraving a full set of silver keys would cost around $1500, and engraving a full set of gold keys would cost around $2200.  So, if you are thinking about this option, it is certainly possible -- and easiest to do when you send your flute in for an overhaul.  As always, feel free to contact our repair shop if you have any questions!

Keys are removed for an overhaul -- perfect time for engraving.

Close-up on a 14K engraved key.

Close-up on a key section.

Another view of a 14K engraved key set.

C.O.A.?

Ever hear the term "C.O.A." and wonder what that means?  Well, in the flute world, it stands for "clean, oil, and adjust."  It is part of a flute's "regular maintenance" routine and is not the same as an overhaul.  Details of the C.O.A are below:

The Clean, Oil and Adjust (C.O.A.) is intended to keep your flute or piccolo playing at its peak and to extend the time between overhauls. A good rule of thumb is to have a C.O.A. done once a year. At Powell, the price of a C.O.A. is $300.00 for flutes and $225.00 for piccolos; it includes up to three hours of repair time and is warranted for 30 days. Expect to be without your instrument for two weeks while it is being cleaned, oiled and adjusted.
1. The instrument is play tested
2. All pinned sections are taken apart and cleaned
3. All keys are cleaned out and oiled
4. Tarnishield is hand applied to the flute body to remove as much dirt and tarnish as possible without buffing.
5. The keys are reassembled and the instrument is regulated. Minor pad shimming is done if necessary.
6. The headjoint cork is checked and replaced if necessary.
7. The instrument is play tested.
Exclusions: A C.O.A. is much more limited than an overhaul. Complete repadding is not included. Lost key motion is covered, but key side play is not. Removal of dents (if requested) is extra and charged at the rate of $85.00 per hour, (minimum charge $45.00). Pad replacement during a C.O.A. is limited to three pads at an extra hourly charge plus the cost of the pads.

Footjoints during C.O.A. process

Footjoints after keys have been cleaned