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Larry Doe's Scanner BlogPreserving the content of aging piano rolls. November 21 Tubing the Ampico-A drawerThe machine shop modifications to the cast aluminum transmission frame were successfully executed. It fits and works exactly as the original part.
A little Mill Wax restored the shine to the spoolbox and the drawer frame cleaned up nicely. A few of the removable bottom panels could use repainting but higher priorities prevail. Next, all restored pneumatics were assembled into the drawer. Some careful study and comparison was done between my disassembly sketches and the tubing diagrams I had obtained. This drawer was in original condition and almost completely intact. I was able to make a detailed sketch of all unbroken tubing connections before disassembling it. Between David Saul's 1925 drawer diagram and the popular Amphion tubing diagram, I was able to account for those few broken or missing tubes which were mostly on the bass end of the drawer. This, being a late 1926 type 8 drawer, did not exactly match either of the two diagrams mentioned above. The main difference is in how the reroll circuit components are connected. There is a 5/32 tee fitting with a .046" orifice installed but it is located in such a way as to delay the reroll signal from the tracker bar to the roll accelerator. I believe this is done to give the transmission time to shift into the reroll position before the air motor can begin to accelerate. The pump cutout is no longer teed to the accelerator. It is connected directly to the slide valve on the transmission shift lever. (see sketch provided)
Some additional study was done of my tubing sketches of the piano belly. There were more missing and broken tubes in this area and my sketches contained a number of question marks particularly in the area of the feedthrough blocks on each end of the primary chest. With the aid of the tubing diagrams and my hand sketches, I was able to account for 100% of the missing tube connections. My drawing of these feedthrough blocks has been included in the photo album.
After seeing a number of other Ampico-A restorations and hearing of peoples frustrations trying to replace lead tubing with rubber under the drawer, I decided to try something different. I designed and made a set of fanning strips which arrange the rubber tubing into two neat interleaved layers. The exact number of tubes in each of 4 areas was mapped and the space constraints determined. The Autocad layout proved everything would fit in the available space, so I proceeded to make the fanning strips out of 1/8" thick aluminum sheet. The photos illustrate what an astounding success this was. The main advantage is the ability to remove and replace a single tube if one should ever become obstructed or punctured during the useful life of the restoration.
At one point, I was looking into finding exact replacements for the equalizer springs. My search was unsuccessful and thanks to Noxon-7 metal polish, the original parts will now be usable.
Next, I will restore the take-up spool and do some actual spooling and alignment using a test pump.
Another trip to Keystone is penciled in sometime before Xmas.
November 08 Ampico perforator now producing Atlas rollsThe Mount Mansfield project has been complete for two weeks now. Both WVPS-FM and WEZF-FM are able to operate at full power from the new master antenna. Winter arrived early at the summit and some of the transmitting equipment had to be moved in the midst of a snowstorm. We kept four sets of tire chains on my truck and used it to shuttle up and down the 4.5 mile toll road until the conclusion of the project. There were issues encountered with the Harris transmitters which were reluctant to be turned back on after the move. Many parts had to be shipped overnight and replaced in order to maintain a full-power signal for Vermont Public Radio's scheduled annual fund drive. Upgrades to the intermediate power amplifier were installed. There were many issues with the aging WEZF transmitter as well. The exciter quit the moment it was turned off at the old location and several components in the high voltage power supply fell to pieces during the move. After a thorough inspection and refurbishing, we feel the equipment should have no trouble staying on the air through the winter. All of these repairs were not included in the original quote to relocate the equipment and we have been assured the extra expenses will be compensated. Many thanks to the WCAX-TV 3 transmitter staff; Ted Teffner, Harold, Fred Lavenberg and Russel Fraser, for their gourmet cooking, hospitality and assistance.
After returning home, progress resumed on the Chickering Ampico drawer components. Many brass and nickel plated items were restored using Noxon-7 metal polish. The original and replacement transmissions were disassembled. A cast aluminum transmission had been procured to replace the original pot metal transmission which was still intact but full of cracks and badly warped. The Noxon metal polish did a fine job putting a mirror finish on some of the badly oxidized brass gears (see photos). This replacement cast aluminum transmission seems to have some issues. It appears to have been used for some time in another piano but its dimensions do not exactly match my original transmission. The boss for the output shaft is 1/8" smaller in diameter and the location of the mounting holes is substantially different. In addition, a piece of the frame is broken off which is meant to hold one of the phenolic sprocket wheels in position on its shaft (see photo). I can fabricate a new sleeve for the undersize boss and machine the frame mounting holes to match the original spacing. I can also machine the frame to accept a new bracket for the sprocket wheel locator. Ebay buyers beware. I guess the ultimate solution will be to try and procure one of Bob Streicher's machined brass transmission frames and install the left-over gears into it. If a feeble attempt had been made to install the aluminum frame with its mismatched mounting holes, a serious roll tracking problem would have been encountered. The long drive shaft which couples the wind motor to the transmission needed to have new felt bushings installed into its mounting blocks.
On Oct. 29, I was able to make a trip to Keystone Music Rolls in Bethlehem where I stayed for a few days to setup the Ampico perforator for recutting Atlas 88 note rolls. I succeeded in making a run of 15 exact copies of Paul Manganaro's original roll; "Outside" pb Mabel Cowan. This is one of the best arrangements I've ever heard on an 88 Note roll! It is sure to be included in Keystone's next catalog. While there, a large lot of word stamping sheets arrived. Each sheet contains the lyrics for about 5 rolls. Our budding letter-turner Lulu Mae posed for the photo. Look for Keystones next catalog which will include a selection of word rolls coming soon!
While in Bethlehem, I visited John Zeiner & Sons to check on the progress of the 1926 Chickering. When I walked in, Mike was hard at work on rubbing out the finish of the main cabinet. The timing of this visit was good as I was able to take the finished drawer pieces with me. The photos only show the initial stages of the hand-rubbed finish. I didn't get a photo of the finished drawer pieces but they are amazing. Next, the plate will be installed and the pinblock drilled & reamed, then the new strings and finally the perfect striking point for the new hammers will be established. This should all occur during December. After five tunings and hammer voicing, I will bring my pianist daughter, Katy to do the final acceptance in late December or January. More updates to this blog will be posted as progress is made with the drawer, primary chest, pump, stack and expression regulators. September 27 Wind motor assembledAfter ten days of work atop Mount Mansfield for Vermont Public Radio, I was able to get home this weekend and finish assembling the Chickering Ampico wind motor. The photos show various angles before and after restoration. The old rubber cloth was still tight enough to operate the motor but there was some gummy residue in the crankshaft bushings so those got replaced too. This substantially reduced drag on the motor. I was able to clean up the original stained finish adequately on the pneumatic boards. The graphited slide valve ports were quite worn and needed to be lapped. The slide valves got new bushing cloth and rubber cloth. All metal parts were carefully polished and the manifold block sealed and refinished. All internal passages of the valve blocks were sealed as well. This motor is now quite well sealed and refuses to be turned backward when the suction port is sealed off. Notice the uneven spacing between valve blocks and how this was corrected. 40 years from now, the only clue that this is not original factory work will be the presence of packing leather instead of cork on the manifold. I did not alter any aspect of the timing turnbuckles as these wires can easily break and are difficult to replace. The loops in the ends were not very skillfully formed originally but since the motor is working so well, I'll leave them alone.
I am now ready to assemble and tube the entire drawer. I will need some of the refinished wood pieces from John Zeiner & Sons once they are ready.
September 20 Governor and wind motor done100 more piano rolls have been scanned and uploaded to www.iammp.org . The Chickering Ampico pneumatic components are progressing nicely. I have finished the expression cutout, wind motor governor and most of the wind motor itself. About one more day will be needed to finish assembling the wind motor. That will enable the entire drawer to be assembled and tubed. Remaining are the two expression regulators, the primary chest, the stack and the pump. No news from Zeiner & Sons on the piano refinishing. By now, I would imagine some progress will have been made on the hand-rubbed finish and maybe the plate, pinblock and strings are close to happening.
The photos illustrate the method I used to locate the tiny holes in the cancel pneumatic for the return spring. I inserted short common pins into the existing holes in the wood with the sharp end sticking out. The pins pierce the hinge and pneumatic cloth as these are installed. Later, the pins are pulled out with pliers and the spring can easily be inserted.
The photos also show what was likely to be two reasons this piano stopped working. First, the tempo slide had a severe binding condition which, upon disassembling, was found to have been caused by a split in the wooden box. This split probably occurred at the time of manufacture. The bolt hole pattern in the cover did not match the pattern of pre-drilled pilot holes. 6 out of 7 screws matched, but the one odd location probably was not provided with a pilot hole, splitting the wood and pinching the tempo slide valve. The second fault would have occurred later. This being a warped and cracked tempo aperture plate. These were made of celluloid and all go bad eventually. The new one is brass. Some wood came out with the old plate and I had to mill out a shallow pocket and glue in a thin wooden shim to replace the missing material.
I'm in Stowe, Vermont for the next few weeks to install FM transmitters for Vermont Public Radio at the summit of Mount Mansfield. The wind motor will have to wait for my return. August 27 Third Ampico perforator restoration underwayComponents for a third Ampico perforator were brought out of storage, cleaned and assembled last week. When complete, this original Taft Pierce Ampico perforator will be identical to the existing computer-driven machine now in use at Keystone Music Rolls in Bethlehem, PA. This third machine had been unusable due to a damaged intermittent transmission (used for advancing the paper). Thanks to the stepper motor-driven motion control system designed by the author, it will now be possible to place this perforator back into service. The photos show some very seldom-seen views of the perforator components which were broken down into small enough subassemblies to allow the individual parts to be cleaned and moved into the perforator room. Some components weigh nearly 300 pounds and the assembled perforator is estimated to weigh in excess of 1000 pounds. While in Bethlehem last week, we were fortunate to entertain Ray Scheffy, Paul Manganaro and Randolph Herr. These fellows brought some of their favorite rolls for our enjoyment and some of these rolls are now in the queue to be scanned and recut. Later, we went to Paul's place nearby for a tour of his beautifully restored collection of automatic musical instruments. The 1926 Chickering Ampico grand is progressing nicely. The new soundboard is installed into the case. The plate is beautifully gilded with new decals and felts. The new bridges are finished and installed. All cabinet components are in the spray booth being prepped. A new bench is being made up from scratch, reusing only the original lid. I've restored most of the pneumatic drawer components and the expression cutout is in process now. It's looking like another 10 weeks or so for completion of the piano by John Zeiner & Co. Before and after photos have been provided for several of the pneumatic components.
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