Headquarters Post 2 the layout.

As we enter the design phase of our project, I'd like to share a few pictures so you can have the before and after experience. This is quite a project and the end result will be impressive, especially if you see what we are starting with.

For pictures I'm going to show you an aerial view first, then the street level pics will make some sense.

So, below is an aerial view of the building. Notice that we're right on the tracks? Should we need it, I can request that a train stop right outside the back loading dock. As the building is only 9 blocks from a major port, this may be useful.

I left the building next door in the shot for perspective. There is a tractor trailer parked there. It amazes me how small the tractor trailer is compared to the building!

So, here's the tour.




Section A: The Shop.
This is all MusicMedic.com's new shop. At nearly 20'000 sq feet, it will surely provide ample room for us. There will be more room in section D should we want to expanded further. This part of the building is the one we are most excited about. I am in the process of designing the offices and and shop portions of the building now. The offices and shop will be partitioned off from the rest of section A, leaving room for manufacturing and a warehouse space.

Section B. The Parking Deck.
Notice in the picture that there is very little room for parking? This was a huge consideration when we bought this building. There is a lot of building but only a few on-site and street side parking spots. To solve this we are going to take section B and turn it into a parking deck. It's about 8500 sq. feet and will hold plenty of cars. Right now Section B is just like the rest of the place. It's a huge open concrete room with concrete pillars. We have a great architect working on the plans to make this part of the building a parking deck. It's going to take a lot of work including building a ramp, fire exits, some major ventilation and the addition of a few large, fireproof bay doors. When it's done, it will be a real convenient space for everyone to park indoors.

Section C: Home sweet Home
I'm going to take this portion of the property and live in it! Section C is the original building, it was built first and differently than the rest. This building is free standing, it shares no walls with any other buildings on the property. Like the other parts of the building, it's got a concrete floor, is an open room with pillars and is one story. Unlike the rest however, the walls are block, the roof is wood and the pillars are made from wood, not concrete. There are windows along one long side which provide plenty of natural light. We will add glass block windows along the other side for more light. The rafters inside Section C are very cool and totally exposed. It has the feel of an old mill right now. I've seen some very nice homes in our area where this exposed wood look was integrated with a steel frame. The steel beams were covered with wood to make it look like the wood held up the place. Our home will have the real thing and will most likely have an urban loft feel to it.

Section D: The future:
I've had many conversations with various music related entrepreneurs who are considering section D. Eventually we may want to expand into this section but I think we have plenty of room in the rest of the building for now. We will have over 7000 sq ft of indestructible lease space with outside and indoor parking and a loading dock outside. There is also a large Bay door that opens into the parking deck. I am always open to hearing your ideas if you need warehouse space for your products.

OK back to my repairs... more on the Headquarters later.

-Curt

If you are reading this blog, there is a good chance that you, through your patronage, moral support and friendship have helped MusicMedic.com grow and thrive. For this, all of us at MusicMedic.com are thankful.

For the last 2 years, we have been looking for a new location for our business. We needed a space big enough that we could grow, allowing our shop and supply business to expand at a more natural rate. Our current location is too small, and we need more room! Also, we are currently in Southport North Carolina which is a beautiful town on the Cape Fear River, but all of us at MusicMedic.com teach and play gigs in Wilmington North Carolina. I'm happy to say that we now have a very cool new building in Wilmington. It will be a lot of work to get it up to date and make the improvements that we are hoping to make, but when it's done it will ROCK!

About the building.
This building is 40,000 square feet (that's nearly an acre of building). There are 4 loading docks, a courtyard, offices, and a warehouse. The building is completely concrete; floors, walls and ceiling, and has withstood any and all storms to date without damage. Architects and builders that we have had in the building say it is the sturdiest building they have ever been in. When complete the new MusicMedic.com building will have limited access indoor parking. This means customers and employees will come to MusicMedic.com, punch in their code, or ring the desk, then a large door will open at the top of a ramp. They will drive into the building and park their cars in the indoor parking facility. From there they can walk into MusicMedic.com!

We have a lot of plans for this new building, and I hope to share some these ideas here on this Instrument repair blog. We are lovingly calling the new building "Headquarters" so every blog about the building will have Headquarters in the title. This will make it easy for you to find new updates on the building.

Next time I stop at the building I will snap a few shots of it so you can see it for yourself!

Update: We have received a huge response to this blog post. So, this blog entry is now an article on our site.

Here is a link to the Tone hole article:
http://www.musicmedic.com/info/articles/num_39.html

Here is a link to all our articles:
http://www.musicmedic.com/info/articles.html





Leveling Sax Tone holes

For years we have been working in the shop on saxophones and leveling tone holes. After trying several different techniques, and many different tools, we have now achieved a new level of success. That is, if you measure success based on the quality of the job produced taking into account the time. At our worst, we used to spend as much as 6-8 hours at the bench leveling, de-burring and polishing the tone holes on saxophones. Now that Job is reduced greatly and takes us less than ½ the labor. The results we are achieving with this method are faster but they are also better in many ways.

The procedure I'm about to outline may seem extreme to many technicians. If you do not know the level of work we are producing in our shop, you may think this method is too fast with a great likelihood of damaging the instrument. Consider that we are a saxophone-only repair shop that caters to the needs of professional players around the world. The lever of our work is very high and most players that find us demand perfection. Don't be scared by the idea of using a drill, if you try this technique, you will find it to be less damaging and more precise than the method you currently use. If this is not the case, please contact me and let me know the method you are using!

A bit of history:

At one time, in our shop, we were using a tone hole file similar to any file that one draws on metal to cut. This file works fast but the cut is not often flat and the file will not reach every tone hole. Further, the results obtained with a draw file are far from smooth and flat tone holes. We quickly switched to a round brass disc covered with sand paper to cut the tone holes down. This method was a little slower than the file but the results, due to the round cutter, were more consistent. Using different grits of sand paper, we were able to bring the tone hole to a nice polish removing even the smallest scratches in the tone hole surface. Shortly after using sand paper, I began to use the diamond grit JS files (which we now offer at MusicMedic.com). The Diamond grit on these “files” is very useful for cutting brass. The time taken to level tone holes was greatly reduced and the jobs were more consistent. I wrote an article about this technique which can be found in the articles section of our site. The resulting finish to the tone hole was not as nice as the sand paper but the the job was good. To compensate, we would finish out our cutting by lapping the tone holes. To accomplish this, I cut a series of steel discs on the lathe and precision leveled them. Using the lapping compound in place of sand paper, we could get better results than sandpaper. After experimenting to reduce the time and improve the job done by the Diamond tone hole files, we came up with our current method and I believe that we now have a very useful procedure that is not only faster but produces a finer job with less burrs and an even tone hole surface.

This method is very easy to use and the results are excellent. We have found that the drill method cuts fast on a non-level tone hole but it cuts very slow on a level tone hole. So, leveling a tone hole with a drill takes only about 20-60 seconds. However, cutting too much metal off the tone hole is very slow. Once the tone hole is level cutting too much would take a long time. To test this we leveled and cut a tone hole right down to the instrument body. Leveling that tone hole took about 1 minute, cutting it off completely took about 15 minutes of constant drilling.

The Procedure:

Leveling tone holes with a power drill the procedure.

What you will need, MusicMedic.com's Complete JS tone hole set with extra pilots and the drill file extension. This will be on the site soon. Email us to order the Drill File Extension, the other parts are on the site.

UltiMax medium weight synthetic oil.

A cordless drill with a low speed around 320rpms.

The procedure of leveling tone holes using a drill is excellent in that it removes human error. The rotating file is held in the tone hole via a pilot and spun under power by a drill. If the technician does not touch the file itself and light pressure on the file is used, the resulting cut will be smooth and even.

1.Insert the long file extension rod into you drill chuck making certain that the drill is set at about 320rpms. Set this drill aside.


2.Choose a file disk that will fit on top of the tone hole without colliding with nearby posts or guards etc.


3.Choose the largest pilot that fits inside the tone hole.


4.Screw the pilot onto the file. Shown here front and back.


5.Apply UltiMax medium weight oil to the file surface.


6.Place the pilot/file combination on and in the tone hole.



7.Hold the instrument with a cupped hand behind the tone hole that you are planning to file.


8.Place the rounded tip of the extension rod into the Allen bolt on the file.


9.Start the drill and cut the tone hole for about 5 seconds.

10.Remove the file and check the tone hole. Note where the tone hole is getting cut and where it is not. Then flip the file over and put a leak light into the instrument. Using the flat side of the diamond file, you should be able to see your progress.


11.Continue to cut the tone hole down with the drill and check until your work is done.

12.As you become more accustomed to this process, you will not need to check your work as often while cutting. You will also see that leveling a tone hole is very fast but cutting it down after it is level is a time consuming process. This is a good thing!

13.When the tone hole is level, you can de-burr using any procedure you were using previously. I will outline our procedure in a later entry.

Good luck!

Curt
Update: We have received a huge response to this blog post. So, this blog entry is now an article on our site.

MusicMedic.com is going to Germany to exhibit at the MusikMesse again this year. If you are going to the Messe in Frankfurt next week, stop by our booth and say Guten Tag!

MusicMedic.com will be in Hall 1.1 booth A22.

I'll also be giving a clinic at the Conservatorium van Amsterdam for the Students of Arno Bornkamp which will be open to the public.

(http://conservatoriumvanamsterdam.nl/EN/home.jsp)

The Clinic will be on various matters relating to saxophone repair including some basic repair concepts as well as Tuning and Toning. I hope you can make it!

Details:

Location:

Amsterdam Conservatory of Music
Conservatorium van Amsterdam
Van Baerlestraat 27
1070 LP Amsterdam
room 052

Time:
5pm-7pm
Thursday 20 March

Go to desk at reception, ask for the saxophone repair clinic, room 052. The receptionist will point the way. The front door is always open, but they have to buzz you in the door to where the rooms are.

Auf Wiedersehen!

The most reliable way to purchase a new woodwind instrument made in Asia.

One of the most common questions I get is “which student instrument should I buy?” If you have searched for an inexpensive woodwind instrument made in Asian such as Flute, Clarinet or Saxophone, you know that there is a lot of information out there. You are probably also aware that there are many different opinions in regards to which instruments are well made and which are not. There are just too many manufacturers, too many brand names and too much hype when you are looking at the instruments manufactured in Asia. The search can be maddening. It can also be risky. Purchasing an instrument that is an unknown brand without knowledge of instrument manufacturing or the opportunity to play-test may result in wasting money on a poor quality instrument that will probably cost more in the long-run to repair than it originally cost you to buy.

I believe I can help you find a quality instrument at a good price. I can find you an instrument that plays great and is well constructed for less than you can expect to pay elsewhere.

First you need to understand the Asian instrument market:

MusicMedic.com works closely with many Asian manufacturers. We visit with these manufacturers while attending numerous music related trade shows. As a result, we have gained a solid understanding of the Asian instrumental market; who is making which instruments; who is using which parts in their own manufacture.

One thing I have come to realize is that many businesses in the US who sell Asian manufactured instruments do not know where the instruments they buy are produced. Although there are many brand names, there are surprisingly few manufacturers of complete saxophones. Factories will often import parts for instruments they produce. There are some companies that only make certain parts; bells, necks, etc. There is an incredible amount of trading going on at various levels. Businesses involved in this trading call themselves manufacturers even though most of them do not manufacture anything. They just purchase parts and assemble the instruments. So the question, “Where is this instrument made?” becomes very difficult to answer. The question, “Who makes this instrument” is even more difficult to answer.

Something else to keep in mind is there are US companies that buy these instruments and private label them. This compounds the aforementioned questions. In addition, there are companies in the US and abroad who buy from various manufacturers, assemble, label and sell instruments. Some of the US companies that buy these private-labeled instruments are not aware they are buying from a distributor, nor do they know who built the instrument they are selling. They have been lead to believe that they are purchasing from the manufacturer, when in fact, they are purchasing from a distributor. They may not even know in what country the instrument was made. The company they purchase from may not know where the parts were actually made. Purchasing an inexpensive, well-constructed Asian made instrument is extremely difficult.


“If I try a certain brand of instrument can I be reasonably assured that this Brand is OK?”

If you buy a "brand x" instrument made in China, it may have been made anywhere in China or Taiwan; possibly both. If 2 years later you buy another "brand x" instrument it may be made in a different place. “Brand-X” may insist (and believe) that their instruments are made by the same factory they used for the past 2 years. In short, the answer to this question is, “No, you cannot assume the instrument is in any way the same as the one you tried.” You need to play test every instrument you purchase. This is true now more than ever.



“So, why can I trust an instrument from MusicMedic.com?”

MusicMedic.com is in the unique position of having an intimate knowledge of instrument manufacturing, a staff of professional players for testing instruments and an established relationship with many manufactures. We are also a professional repair shop.

This year I will be meeting with many manufacturers at various trade shows. I know most of these manufacturers personally. I am a working professional woodwind player, as well as the owner of both a world renowned instrument repair shop and woodwind repair tools and supplies distributor. When I go to the largest trade shows, I will have at least 5 woodwind players and 3 repair techs with me. We will be play testing every instrument we can get our hands on. This alone effectively cancels the risk I have outlined above. We will play test the various instruments at the shows (and there are many to try) purchasing only the instruments with good tone, intonation, and quality craftsmanship. When possible, we will purchase from manufacturers we know. This further assures us and you that we are buying good quality instruments.

The names on the instruments we purchase will all be different but many will be from the same factories. In the past I have had very good luck with the instruments I bring back and have never had one returned.

“What is the process for purchasing one of these instruments from MusicMedic.com?”

Instruments are purchased on an 'as needed' and 'as available' basis. If there are not enough good instruments at the show to cover the demand, those who do not get an instrument will be given the option to keep their place in line and wait for the next show or have their deposit returned.

When we return from the show we send the instruments through our repair shop to be properly set up. Then we play test them again. Once this thorough process is complete, the new instruments are sent to those that have requested them. You will get an instrument that is well-made, play tested several times and regulated in our shop.

To purchase a woodwind instrument with our service:

1. Fill out this questionnaire located here: http://www.musicmedic.com/info/horn_form.php
2. Contact Curt@MusicMedic.com with any questions.
3. We will contact you via Email to pay your deposit. See deposit schedule on the horn form.
4. We will find an instrument that is right for you at the show. Hurry, the next show is just around the corner.
5. When we find a good instrument, you will be asked to pay the difference between your deposit and the actual cost of the instrument.
6. The instrument will go through our shop where it will be tested for leaks and play tested again before it is double boxed and shipped.
7. Enjoy your new instrument!