onehand instruments

Before starting anything, I have the design ready. In this phase I start with structural design. Then I measure up the donor instrument. All lengths, diameters, movement angles, and construction details go into a spreadsheet. From there, detail design starts. From the start I must know that when a key is pressed 8 millimeters here, another key moves 6.5 mm over there. Another concern is that I have to fit a lot of moving parts in a small space, which is quite a puzzle.

In the new design, some of the many tone holes become redundant. For example, on a “normal” saxophone, there are 3 ways to play bB. Two of these are done with right hand, so they cannot be used anymore, including the so-called side-bB. These redundant holes are removed. Some of the high note holes will have to be operated in a different manner, as they were formerly operated by the right hand. This calls for a complete redesign of this section, leading to the remocal of a section of the instrument body, and replacing it with a new part, with newly placed and holes. Also their diameteres will be recalculated as this key group will work differently.

You need all fingers of your hand available to operate the keys. That’s why the saxophone needs to support itself somehow. It may stand on the ground or be suspended from your shoulders. The existing straps just hand the saxophone on a single point on that back of the sax. That is OK with the right hand also there for support. Without that right thumb, it will not do for one handed playing

This is the majority of the work. Each key starts by construction of pillars, which are made from scratch. They have to fite the body curvature at the base to make a strong connection at the weld. The pillars support the axle steels, precision ground steel rods. These work as bearings for the key tubes, which are precision turned from brass. This is the moving system, and it forms the base for the key, which has extensions to receive a spring, to be operated from another key or touchpiece and often an extension to reduce the movement range in a precise yet silent manner. A simple key is not that difficult to make, it is the interaction between keys where matters get complicated. And that is exactly what the key do that I create to make a saxophone for one hand playing.

There is only one way to join brass parts that will stand the forces upon them, and that is silver soldering. Parts are covered in chemicals to allow the flow of the solder. Then parts are held in heat resistant supprts to keep everything in place, and heat is applied. Only at 650 degrees C the solder will flow to form a strong bond. After cooling down, the chemicals must be washed of in sulphuric acid. No less that 50 of these solder joints are neccesary.

Once all sawing, filing and soldering is done, the saxophone body is covered with discolorations from the heat of the soldering. The new keys look rough and dull. First parts are finely files and then sanded. Lastly a polish is applied, using a buffing machine. Once everything shines as a saxophone should, the pads , felts and cors are re-applied. The entire instrument must be very precisely adjusted to all keys closes the the toneholes with the least amount of pressure.

Finally, there are costs of parts and materials and shipping.

EU customers pay VAT.