As the bocal did not come with the instrument, I check the cork size with some generic wing joint tops

The customer would like it to be returned to how it was made, something similiar to the one in this photo

Opening it up, we can see its set up a straight pipe unit

One Bocal, nicely packaged

Remove the cork

Bocal Reshaping

Not all Bocals can be repaired, they are one of the hardest items to remove dents and folds from IMO

Set the bocal up, so we can pour the liquid in

As the wall thickness of a bocal is around 10 thou, or .025mm for metric people we use something that will not expand when it cools off, this is called cerrobend

Using a ladel, we melt the mix

Pour it into the bocal

Like so

Liquid, ready to be poured

Let it sit for an hr in the freezer

By feezing the bocal the crystalline structire of the mix becomes more malleable in the re bend process

A simple hand bending unit

And we start

The original bocal with some reference points for me to bend too.

Slow steady bends against the roller

Slow and steady

During the bending process, we sometimes can feel the tubing stiffen up. This is some form of work hardening of the tubing and cerrobend or resistance occuring between the two mediums.

Typically I stop at this point, and then re-warm the bocal back up to soften the cerrobend again and then refreeze it before proceeding with any more bending.

Tweak some final radiuses into place

We then wash and clean the mix out from the inside

and

Wash it again with a brush and some alcohol to remove all residue and again and again until its super clean

New cork

Sanded and finished