Sax Mech Rep P8

With the body tube supported, using a hammer we tap the post, light blows until its further than we need

Light glancing blows with a hammer, tap it back into alignment until the rod freely travels through the post.

This method of over straightening minimises any future settling of the metal.

Now posts are aligned, we are going to replace this monstrosity of a rod screw that had been use. It is too long and should be flush with the end of the post, it should also have a screw slot in it

The Rod screw will be replaced vee Repair 6 after redrilling support posts

These posts are fitted to a rib which is then soldered to the body, if they were individually soldered posts, one could unsolder and move them instead.

To prevent body tube distortion, insert a body mandrel internally to support the round tube shape

Mis-aligns a good 1.4mm

New Rod screw is 112 tho, which is 3 thou oversize, less than the thickness of an A4 piece of paper

We take the end of the Rod screw and reshape it so it becomes a cutting tool for drillign out the stack support posts

Add an extension to the rod so my battery drill is out past the end of the saxophone

No guides are needed, basic hand skills can keep it accurate as it is a very long rod and easy to set squarely

Stop before we cut through the threaded end post

Grind half the diameter away

Relieve the end 10 degrees

Back relief 3 degrees

Up close of the drilled hole and hand made D bit

I add a little bit of cutting oil (brown in colour) and move the Rod Screw in and out a couple of times to smooth the posts bore

We use the Hand made D bit to also Ream out all the lower stack keys G#/F/F#/E/D

Example - a dark shadow exists on the left side of the post, so post has been relocated further than it will be when at final rest.

We convert our reamer now to a Rod Screw, simply cut the head of the cutter off and replace it with a screw thread as per Repair 6

Original rod screw is 109 thou

A new rod screw was made as per Repair 6

Hinge tube was lengthened and tightened as per Repair 7

Reciever post was rebushed as per Repair 8

Finished Palm D

Removing keys, I start the lower stack repair with just the rod back in place, when we fit the rod it hits the upper D support post, so its mis-aligned

Lower Stack Assembly

Assessing it as an assembly, we find the following

Rod screw is rusty and too long
G# Loose on rod
F# has end play
F# is 2 thou loose on the Rod Screw
F is loose between posts a little bit of looseness on Rod screw
E is loose between posts
E is loose on Rod screw
D Is loose between posts
Rod screw is loose in 3 of the 4 support posts

Type 9 Repair, Mis-aligned stack post

Repair is carried out to re-align exisiting post with surrounding posts using original rod screw

Lower Stack D - Upper Support Post

Lower Stack Post Reaming

Type 10 Repair, Reaming a Multi Stack post assembly with a hand made Reamer

The black shadow indicates areas where the post and Rod screw are not in contact, this is poorly supported and will lead to pad closure issues