Top ten reasons why finishing my piano is taking so long

10) It won't cooperate. Let's face it: even inanimate objects can be a bitch sometimes. This thing goes out of tune if I look at it cross-eyed. It's discouraging.
9) Runner's knee. Had it for four weeks. Doctor says I'm not a five-foot-five, 110-pound Ethiopian and that I need to run in shoes instead of barefoot or flats. Seriously, though, the single most painful activity with runner's knee is standing - the required posture for tuning a square grand.
8) I can't see the end so I'm reluctant to work toward it. I don't know what else to say about that.

I guess there are only three reasons.

Day 90 –Sunday, June 26 – Rain outside, gloom inside

Goals: Work on it

Music: Doing some tuning, so none.

A bad case of runners knee and cloudy skies and the threat (and actual falling) of rain more or less forced me to work on the piano. A while back when I inserted the keys, I realized that I had some double strings that I had tuned as if they were singles, meaning that my piano was severely under-tuned in the lower register. I set about correcting that. So, to be sure I had everything correct, I started at middle A, which, diligent readers will remember, I tuned to G# to lower the stress on the piano. Unfortunately, I seemed to have miscounted, probably because of the double strings I counted as singles, and what should have been G# was actually at F. Cripes!

So, starting at middle A, I moved everything up so that all the keys would be a half tone flat. That meant tightening everything. That meant finding some pins that couldn’t hold tune because of the increased stress. I wanted to get at least half the keyboard done, but standing up in that awkward posture made my knee start hurting too much, so I wasn’t quite able to do half the keyboard. And at that, I had four strings that were untunable. I might try for a whole tone down to see if that makes life any easier for me. Anyway, I could only work for an hour and half, but that was enough. The piano is getting closer and closer to being a decorative piece and not a musical instrument. I swear if things don’t start going right with it pretty soon, I’m turning the sucker into a bar.

Studying Up

It’s hard – no, make that impossible – to work on much of anything whenever you get called in to work on the weekend. This happened to me two Sundays ago and last Saturday, so progress on my piano has more or less ground to a halt. Because of my ruined Saturday, Sunday was overly hectic, but I did find time to leaf through and read my piano repair manual and try to figure out what to do with the wippens that are killing about fifteen of the keys in my piano (if in fact it is the wippens – there may be some fit issues with the hammers as well). In short, at this critical and hyper-detailed juncture, I’m not finding much help for my square grand in a manual that focuses almost exclusively on grands and uprights, not to mention the frequent detailed passages about Steinways. I was able to glean a few ideas from the book, but I’m still not really sure what is going to be the best way to repair the keys that keep dying. I expect it will require some experimenting.

So, this coming weekend, I think I’m going to move to some cosmetic work. Probably work on the mother-of-pearl inlay some and maybe even go back to the stool again (I’ve got the brushes for it).

I need to be pushing a little harder on this.

A Night with a True Jazz Legend

Wednesday June 1 found me and Mrs. S once again in Birmingham AL, to attend a jazz concert at the Alys Stephens Center for the Arts. We sure spend a lot of time there for it being over a one and a half hour drive from our house. But when a guy like Herbie Hancock is performing in your neck of the woods, 90 minutes seems a pretty reasonable drive. As part-time patrons with dedicated front row seats, it’s hard to pass on an opportunity like this, so naturally, we also signed up for the VIP “Meet & Greet” package for our chance to meet the legend and possibly have a few photos taken and get a few CD’s signed. Imagine our surprise then when one of the event coordinators told us that his contract did not allow for either. (Turns out he did both.)

So come time for the concert and it’s mostly empty seats, but they filled up pretty quickly and the show started maybe only ten minutes late. Herbie’s drummer comes out and he starts right into a funky syncopated riff that I couldn’t see how he could keep going but that he did and never missed on. The bass player wandered on stage and it took him about thirty seconds to get to his five string axe, attach the strap, and get it settled before laying a line down on top of the drums. So, they’re on the right hand side of the stage, wailing, and I’m all caught up in the beat when out of the corner of my eye, I catch a glimpse of glittering orange, and there’s this tiny old guy moon walking toward the keyboard pit. (Yes, moon walking!)

And the crowd goes wild!

And those turned out to be the two main themes of the night: a little old dude who should be laid out on a recliner or playing bingo somewhere, funkin’ it up on a piano, computerized synth, and a keytar, and a bunch of people screaming at him as he does so. Which is also what got me: Here’s a guy who released an album in every one of the last six decades, has more than fifty albums of material to choose from, is over seventy years old, can do anything he wants musically and professionally, and if he was taking it easy and swinging through a quiet version of “Watermelon Man” or letting some singer take the lead on one of his compositions while he sleepwalks (instead of moon walks) through the comps and a canned solo, everyone would still be appreciative and crazy, but instead, he’s out there with a freaking keytar, jumping around like a four-year old with a squirt gun on the first day of summer as he bangs away on “Actual Proof” or “Chameleon”. What’s going on?

I’ll tell you what: Herbie Hancock is going on. And on, and on, and on. No wonder his latest album involves musicians of eleven different nationalities singing in seven different countries recorded in four different studios. When you’ve done as much music as Herbie, that’s the only way you can get to something new and fresh. Stunning.

Honestly, the concert made me dizzy and I don’t think it was from the drive and the stifling 95-degree heat. Herbie did mostly new stuff from his Imagine Project recording, which I have a hard time classifying as jazz but which I enjoy immensely. I was especially psyched when he and his two man band and one woman singer did my favorite track from the work, Tamatant Tilay/Exodus. Everything else he played, he played as funky as possible, spending probably 40% of his stage time on his Roland keytar. His piano, a Fazioli concert grand, didn’t sound real. His playing sounded fresh, whimsical, and inspirational. Somehow. The supporting band members were solid musically and just, everything was great. Words escape me.

Our signed copy of "The Imagine Project"

The meet and greet session started  frightfully stiff. Only one guy seemed truly comfortable talking with Herbie, and they started talking about, like, Herbie’s third album, released the year after I was born. It was sort of electric just hearing Herbie say the name, "Miles Davis".  Anyway, to get things moving,  the coordinator jumped in and made everyone get their pictures out of the way so Herbie wouldn’t spend the whole night standing around with our lot. When I went up to meet him, I had him sign our copy of his latest, The Imagine Project, and we took two photos before Mrs. S joined in. Then he spent the rest of the time chatting her up. Later, when Herbie was done with the photos, he wandered over to the fruit tray, where Mrs. S and I were, so we talked a little bit more and Mrs. S had him sign our copy of “Maiden Voyage”. (I like his signature. He writes so you can actually read his name. See above and below.) I literally had a whole stack to be signed, but we were being reserved since we were told right out of the gate that he wouldn’t be doing that.

Our signed copy of "Maiden Voyage"

After he’d had a few pieces of fruit, he looked around for something to say and do, but the coordinators gave him the go ahead, so he waved, and was gone. He’s a very nice, personable, agreeable gentleman. He’s small, but his hands are firm and supple. His smile is bright and his eyes even brighter. He doesn’t move fast and his hair is thinning, but he’s genuine, real, meticulous, and true to his songs when it comes to his music. I think top to bottom, meeting Herbie Hancock was one of the most satisfying and valuable experiences I’ve had in my short four year jazz career. I may have been late to jazz, but I’m catching up fast.

Days 88 and 89 – Saturday and Sunday, May 28 and 29 – Looks like a piano!

Goals: Finish with the leather on the hammers and install the keys

Music: Shelley Manne and His Men’s “Complete Live at the Blackhawk” (all four discs).

With the keys inserted back in the piano, it again looks like a piano and the temptation to chop it into a desk or a bar is reduced. As has been the case throughout this project, however, the piano continues to beset me with “good news, bad news” scenarios:

-Good news: I successfully manufactured a replacement hammer from scrap hammers purchased online. Bad news: I wasn’t actually missing a hammer. The space on the hammer assembly is for something else. (Wish I knew what.) At least that explained why I ended up one piece of leather short when I was adding leather to the hammers.

-Good news: I successfully rebuilt the pivot arm end of a broken hammer. Bad news: The difference in shape and size is just enough that the wippen didn’t pick it up and project the hammer correctly. Hard to believe when you look at the photo – we’re talking a fraction of a millimeter difference! (I ended up shimming the whole assembly to make it work; it still joined the ranks of dead keys after the first go around.)

Top is the replacement, bottom is an original. Yeah, they're different, but...

-Good news: I finished putting the leather on all the hammers. Bad news: Even with careful and thorough trimming, the tiny size differential makes many of the keys stick, both against each other and against parts of the piano when the keys are reinserted.

Hammers all covered in leather and ready to go.

The pile of leather chunks that took be two days to trim from the heads - and they still don't work right.

-Good news: I was able to insert the keys and a number of them actually hit on the strings they were supposed to and made a passable sound. Bad news: After playing once through the keyboard, any number of keys went dead, or took some jiggling to get playing again, or didn’t sound at all in the first place.

-Good news: The rough tuning of the piano means I have actually gotten a reasonable facsimile of harmonic sound from the strings. Bad news: Not realizing that some of the “single” bass strings were actually “double” bass strings, I’ve got the piano tuned to play more notes than there are keys.

Good news: At the lower end of the keyboard, all the keys work. Bad news: The ones that are supposed to be hitting double strings are only hitting one string. (Maybe it doesn’t matter if I tune them or not.

Memorial Day will be filled with tuning work and key adjustment. I’m even going to have to get my piano repair manual out and see what my options are with the wippens that aren’t triggering the keys right after I just fixed them. (I mean, of course I made sure all the keys were working before I reinserted them, but I didn’t think so many would go dead right out of the gate!)

One more: Good news: The soft pedal actually moves the damper assembly into position and deadens the hammer strike on the strings. Bad news: It doesn’t go back on its own. More adjustment! 

Days 86 and 87 – Saturday and Sunday, May 21 and 22 – Devil in the Details

Goals: Put the leather on the hammers, install the keyboard assembly after checking that everything works

Music: Humphrey Lyttelton’s “The Parlophones” (all four discs); Bud Powell’s “The Amazing Bud Powell, Volume Three”; Buddy Rich’s “The Best of Buddy Rich”; Max Roach’s “Freedom Now Suite”.

Delicate, boring work. Boring and delicate. That’s all that separates me from a completely refurbished antique square grand piano: boredom and delicacy.

All I did on Saturday was cut the leather strips for the hammers and glue them to the hammerheads. That’s “all”. As I recounted in my last entry, I did not want to do this in stages because I was afraid of mixing the lengths. And, because I was using contact cement, I wanted them to be done all in one fell swoop. I was a little non-committal about whether I should put glue on the entire head and strip or just glue the ends with the body of the strip stretched over the hammerhead. I opted to leave the middle glue-less to give me some land to handle the strips with. This turned out to be a fortuitous decision, as I will relate in a moment.

One I got to cutting and placing the strips, I noticed they were all just about the right width, but most of them were too long (not sure why). Some I cut, some I used the extra surface for stronger adhesion. This, too, turned out to be fortuitous. Anyway, it took about four hours, but I managed to glue all the strips to the hammerheads.

On Sunday, I reviewed my work and naturally, all the strips were jamming into each other, causing all the keys to stick, pull multiple hammers, and not return to the down position properly. I expected this, and was sure they’d have to be cut. Here’s where not gluing the entire strip to the hammerhead paid off: I could trim the leather strip without having to trim a fat portion of the felt head. Nearly all them went smoothly. Some I could get just with the small pointy cosmetic scissors, but the majority required being held with tweezers while cutting with a razor. Due to placement issues, some I ended up cutting close to only about an eighth of their original width. That’s where the extra land for adhesion came in handy (for those strips that had it). Unfortunately, with my poor eyesight and inexperience, some of the strips I cut right through, releasing one end of the hammer. I used super glue to reattach these, not wanting to fuss with the contact cement any further. At the end of the session on Sunday, I was about twenty keys from the end, but that’s actually much closer to the end of this stage, because the high keys, which sit almost directly perpendicular to the strings and parallel to each other will not need any trimming. (Hooray!)

I have at least two wippens that will need adjusting before I can install the keys. Then, the sound of hammer hitting string and generating music will again emanate from my piano, almost one year to the day since the last note was heard from it.

I bought some clear acrylic resin that I’m planning to use to fix up the mother of pearl inlaid board. If I can get that to look pretty decent and the piano to play, I will have 99% succeeded in the refurbishing of this piano.

Days 84 and 85 – Saturday and Sunday, May 14 and 15 – Andddd...........next!

Goals: Finish the piano

Music: Gerry Mulligan’s “Original Quartet with Chet Baker” (both discs); Bennie Moten’s “Band Box Shuffle” (both discs); Paul Motian’s “The Sound of Love”, Fats Navarro and Tadd Dameron’s “Complete Blue Note Recordings” (both discs).

With jazz improvisation class finally over, I have nothing but time for working on the piano. And after my trip to Memphis where I saw Francis Scott Key’s square grand piano and the non-functional shape it was in, I’ve been feeling a little inspired to get my piano back into operation. So I set to work.

Needless to say, there’s nothing left but a lot of little jobs, most everything cosmetic. I just take each job as I think of it and in whatever order necessary to complete the work properly. I obviously needed to get the key and hammer assembly back in, which meant repairing the one broken hammer and fabricating the missing one. Using spare parts that I bought on e-bay, I started with repairing the one broken hammer. It just needed a new pivot head (I’m calling it – I don’t know what it’s called). Not knowing how much of the shank goes into the pivot head, I decided to split the old one to see for sure. Here’s what that looked like: 

Bottom shows pivot head in mount assembly. Those pieces are the old pivot head. Uppermost is the original hammer and shank.

After that, it was an easy enough job to remove one of the old pivot heads from the spare parts, drill and scrape out the old shank bits, and sand and shorten the actual shank to fit into the hole. Wood glue and a little eyeball measuring next to the other hammers, and it was ready to install:

Repaired hammer ready for installation.

Manufacturing the replacement hammer for the one that was missing was a bit trickier and time consuming. Because the hammer has to fit between a bunch of other hammers, it needed to be sized correctly, but all of the parts I got off the internet were for the larger hammers at the other end of keyboard. I thought about sliding all of the hammers down one, but I was worried doing so might create fit issues down the line, especially with the felt pads that catch on the wippens. I didn’t want to deal with that , so I decided to see if it was possible to use my Dremel tool to whittle down the size of the felt on one of the big replacement part hammers to make a small felt head hammer. 

What I started with (left), and what I hoped to finish with, approximately (right)

I found that it was an easy enough process with the only drawback being that it generated a lot of dust, and so I set to manufacturing a replacement hammer, doing most of the felt trimming outside. That was a two day process due to the amount of sanding needed and also having to glue the felt, using contact cement to hold it and super glue to harden it. When all was said and done, I had my replacement hammer:

Left: What I started with; Middle: What I ended with; Right: What I was trying to get to

It fit adequately in the spot that had been missing a hammer for almost forever. (I could tell by the wear on the felt underneath the hammer housings.)

Here you can see how light the felt is where I removed the hammer, but how dark where the missing hammer was. That hammer was missing for a long time, telling me this piano has probably been unplayable - and unplayed - for 50 or more years.

I reattached the wippen stoppers and hammer assembly to the keyboard frame, holding the wippens in place with string when I fitted the hammers back in place. Upon releasing the string, I found all the keys and hammers in working order. (Thank God!) I wanted to slide the keys in to see and hear them hit the strings and hear what it sounded like, but I still had to put some leather over the worn surface of the hammers. What’s next is next, so I set to it.

I marked up the thicker portion of the lamb leather that I will be using to cover the hammer heads with, having measured and calculated that some time ago. 

The leather, ready to be cut (pencil for scale)

I didn’t start cutting up the individual strips, though, because I’m going to cut and glue and cut and glue those individually so that I don’t have to mark them up or anything. I’m not really sure which would be more tedious, cutting all then gluing, or cutting and then gluing as I go, and although I think splitting the jobs would be faster, cutting and gluing in tandem should be easier and make it easier to avoid mistakes.

So, without having enough time to tackle the leather gluing job, including the fact that the outside temperature was too low to open the windows, I moved to some other minor finishing jobs. So finally, I cut a few pieces of felt and threaded them through the strings, working from photos of the original state of the piano (always an inspiration).

I still haven’t figured out what I’m going to do about the missing damper arm. Hopefully I’ll get lucky one of these days and come across some damper arms on the internet. Until then, I’m going to have one low, long-ringing F note.

When I finish the piano, that is.