The Blue Tape, Part II

Pre-cut pieces for body and footjoint

Last week, we took a closer look at the blue protective film that is used in the repair and finishing departments.  In our previous post, we visited with Repair Technician, Rachel Baker, and explained how she uses the film.  This week, we stopped in to the finishing area and chatted with flute finisher, Lindsey McChord, about how finishers use the film.

The most noticeable difference with the blue film in the finishing department is that it comes in pre-cut pieces designed to fit the body and footjoint.  Each piece has a waxy, paper backing that is removed before the film is applied.  Finishers must cover the entire flute (including the keys) to protect it from scratches.  So, the pre-cut, pre-formed pieces of film are extremely helpful for the finishers.  We imagine it would be very difficult to cut pieces of film by hand to fit perfectly around the tone holes, so it is helpful for them to have these pre-cut pieces to ensure consistency and properly protect the flutes.

Lindsey told us that once the flute body is ready for the finishing process, it has already been polished, shined, and buffed.  It's important to keep it this way, so that it remains perfectly intact for the customer -- even in the process of applying the film.  That being said, the finishers do not want to get fingerprints on the body and footjoint when applying the film.  In order to apply the film without touching the instrument, the finishers use a folding fixture as you will see in the photos below.  The fixture can be used to hold the body and the footjoint.  There is a removable section on the end that can be placed in three slots -- 1 for the body, 1 for a b footjoint, and 1 for a c footjoint.  Once the body or footjoint is in place and held securely in the fixture, the finisher removes the paper backing from the film and applies the film to the body.  The finishers will then have to cut pieces for the key cups, which Lindsey says they do by first applying a piece of the film to the cup and then carefully cutting around the outside of the cup.  Once everything is covered, the flute is protected and ready for the rest of the finishing process!

Body in fixture, ready for film!

Applying the film, lining it up carefully to fit.

Done!

Lindsey points to the slot for the b foot (c foot slot is to the left of this).

Inserting the end section into the b foot slot.

Fixture is now ready to hold a b footjoint.

The Blue Tape

We often times post photos of flutes in production or in the repair shop that appear to be blue, and we are asked, "what's the blue tape?"  Well, in actuality, it is a blue protective film that comes on a roll, much like a roll of tape.  However, it is not sticky -- it adheres to the metal like a static decal would to a piece of glass like a window.  The purpose of the blue film is to protect the metal from getting scratched or otherwise damaged during the finishing process or during repair.

When we see flutes in the finishing department, the protective film is on the entire flute body, footjoint, and keys.  We stopped in to the repair shop this week and spotted our technician, Rachel Baker, cutting a piece from the roll as she prepared to start on a flute that was in for an overhaul.  Rachel cut a piece and applied it to the back of the body, because she said that this particular area is what will come in contact with the repair mat -- so the protective film will help prevent scratches as Rachel works on the flute.  In the case of the film being used on the entire body and keys, pieces are cut from the roll, and then these pieces are cut again to the appropriate size and shape to fit the body and keys.  After a flute leaves the finishing department or the repair shop, the blue film is removed, and the well-protected metal is revealed! 

So, the next time you see what appears to be a "blue flute," do not fear -- it is merely a type of film covering the flute to protect it.  The film itself does not harm the flute in any way or leave any type of coloring.

Taking a piece of blue film from the roll.

Getting ready to cut it to length.

Cutting the piece.

Applying the piece to the back of the flute body.

Smoothing the piece down.

Done!

Ironing Pads

We all know that ironing takes out wrinkles in clothing and other fabrics, but did you know that ironing can also take out wrinkles in flute pads?  It's not possible to iron pads with a traditional household iron, but there is definitely a pad ironing tool and a procedure for doing this properly.  We had the chance to catch up with Repair Technician, Rachel Baker, to find out more.

Rachel told us that felt pads are most likely to wrinkle, and it is a new felt pad that is particularly vulnerable.  Why is this?  Well, with a new felt pad, pressure is exerted on the pad once the washer and screw are in place. As the screw is tightened, the washer pushes down on the pad, which can then cause the area of the pad around the washer to wrinkle.  Wrinkles can be problematic when flute finishers and repairmen are using a feeler gauge to check for leaking pads.  The wrinkle itself may pull on the gauge when the key cup is closed, which ordinarily would mean the pad is sealing.  However, this is a "false gauging" because once the wrinkle is smoothed out by ironing, the feeler gauge may pull through, detecting that there is a leak. 

So, how does one iron a pad?  Surprisingly, the process follows the same basic principles as ironing fabrics.  The pad iron is a small, flat hand-held tool as you will see in the photos below.  It is dipped into a bit of water and then used to lightly dampen the pad.  The pad iron is then heated just a bit (and very very carefully) with an alcohol lamp.  If the iron is too hot, it can actually burn the pad, so heating the iron properly is key.  After the iron is heated, it is applied to the pad.  We watched as Rachel "swiped" it in a circle over the pad.  Then, you are done!  The wrinkles are gone, and the pad is smooth!

Wrinkled pad.

The pad iron and a small glass of water.  Iron will be dipped in water to dampen the pad.

Dampening the pad with the pad iron.

Heating the pad iron carefully.

Ironing out the wrinkles.

Done!  Pad is smooth again!

Keeping it Clean

Don't worry -- this can be cleaned!

We had a chance this week to catch up with our Customer Service Manager, Rebecca Eckles, and touch on an interesting topic -- cleaning your swabs and cloths!  We love out instruments, and we want to keep them clean.  So, keeping your flute clean means that you have to make sure the materials you use are clean as well!

Rebecca tests flutes for us here at Powell all day, so she goes through many swabs and cleaning cloths.  At the end of the day, she may find herself with a bunch of swabs and microfiber cloths that are certainly "well-used."  She told us that because she has so many, she takes them home and cleans them simply by putting them in the washing machine on the delicate cycle.  If she only has a few, she may do a quick hand-wash in the sink.  Either way, it is perfectly fine.  You want to make sure that you use a very gentle detergent in the washing machine (like Woolite), and do not use fabric softener.  If you are hand washing your cloths in the sink, you could also use something like Woolite or even a mild dishwashing liquid.  If your swabs are silk (like in the case of a piccolo), you definitely should wash them by hand in the sink.  Whether you are washing cloth or silk swabs and cleaning cloths, do not put them in the dryer -- simply let them air dry, and they will be perfect!

Now, we realize that you may not have a whole load of swabs and cloths to launder, but that is okay.  If you choose to put them in the washing machine, you can always put them in a smaller load -- maybe with some other dishtowels or something similar.  You may want to put the swabs and cloths in a mesh "lingerie bag."  Keeping your cloths and swabs clean will make a world of difference, and it is quite easy to do -- so don't be afraid to do it yourself.  Just remember, it's okay to wash them, but do not take them to the dry cleaner!

Repair Shop Overview

We've written about the steps our technician takes with overhauls and COAs, beginning with an assessment of the flute when it arrives (click here to read the previous post on the COA process).  But, have you ever wondered what happens next?  We frequently visit the repair shop and know that there are multiple flutes in repair at the same time, so we sat down with repair technician Rachel Baker to find out more...

Rachel told us that she usually has about 10 to 12 flutes in the shop at a time.  That is quite a lot -- so how does she keep everything straight?  Well, she gave us a quick overview, which you will see in the photos below:

Flute bodies, footjoints, and headjoints are all kept in order on stands with multiple pegs.  In this photo, the stand toward the back contains flutes in for an overhaul, and the stand in the front has flutes in for a COA.  Each individual flute takes up three pegs (one for the footjoint, one for the body, and one for the headjoint).

Each flute will also have a tray for the mechanism -- as you can see in the bottom right-hand corner of the photo below.  These trays have divided compartments so that the mechanism components can be easily organized.  Each tray has a piece of masking tape at the end marking the serial number of the corresponding flute.

Mechanism steels are small and could potentially be very easy to loose if they are not well organized.  Rachel has acrylic blocks that were made in the shop here at Powell.  The blocks have small holes drilled into them, and Rachel organizes each flute's set of steels, marking areas on the block with the flute's serial number.

Not every repair technician will have the same set-up for tools, but Rachel's looked very unique (as you will see in the photo below).  She told us that she built this tool holder with her father -- and the frame is actually mahogany!  The tools are held onto the top horizontal block with magnetic strips.  The secret behind this block is that it is actually a knife holder from IKEA.  Looks like Rachel has a very practical and personalized way of keeping her tools organized!

Finally, we asked Rachel how she keeps track of the "diagnosis" is for each flute.  She told us that each flute has its own repair paperwork --  a form indicating everything that needs to be done.  Once the flute is completed, the customer receives paperwork with a complete break-down of the repair work completed on the flute.  To schedule your repair online, visit https://powellflutes.com/repair-doctor/schedule?destination=repair-doctor/schedule/repair. 

Separation Anxiety

Last week, we looked at a few notes our repair tech, Rachel Baker, suggested for customers to make before sending their flute in for repair.  Of course, we realize that it can be difficult to part with the flute, even for a short period of time.  A bit of "separation anxiety" is understandable.  In fact, if you have ever felt worried about sending your flute off to the tech, we are here to help put your mind at ease.

We asked our tech what issues seem to concern customers.  She said it's not repair, but rather three main things: damage in shipping, temperature problems, and the flute getting lost.  We'll explain a bit more below:

1) Damage in shipping:  Customers may worry that their flute could get damaged in transit, but Rachel assures us that when she receives flutes, they make it here just fine.  She said that if you are carrying your flute around in its case, and it is fine in daily transit within the case, it should be safe for the longer journey.  Also, if you make sure to package it carefully and properly for shipping, it should be extra safe and secure.  You can read more about packaging your flute for shipping in a previous post at http://www.repairmyflute.com/2013/08/packing-it-up.html.  If there are any problems with the case not fitting the flute securely enough, a case fitting would be done as part of the repair process.

2) Temperature:  This is definitely a valid concern, especially for those sending wooden flutes and piccolos.  Wooden instruments are particularly vulnerable when it comes to drastic changes in temperature and humidity.  If you can send your wooden flute or piccolo when the weather is more temperate, that is certainly best.  But, we know that emergencies happen and schedules don't always allow for customers to send their instruments in a mild season.  If our repair tech receives an instrument that has been shipped, and the temperature outside is very cold, she always lets the instrument warm up to room temperature gradually and carefully before beginning work.  If you receive your flute back from repair on a cold day, you will also want to take it in and let it warm up to room temperature before you play it.  Same can be said for metal flutes.

3) Lost packages: This is probably one of the greatest fears customers have -- and rightly so!  Pro flutes are very expensive, and more importantly, a musician's instrument is worth much more than any dollar amount.  So, customers should always have their instruments insured.  Many instrument insurance policies will also cover shipping.  If you have a policy, take a look and see if you can get shipping covered (if it is not already).  Also, make sure that your Powell flutes are registered.  We also have a previous post (on our Flute Builder blog) about registering your flute: http://www.flutebuilder.com/2013/09/registering-your-powell.html.

Of course, if you have any other questions or concerns about shipping your instrument to Powell, don't hesitate to contact us!

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!