Mechanical failure in the flugel horn often results from internal calcification and the accumulation of organic debris within the conical bore. Unlike the cylindrical sections of other brass instruments, the specific geometry of this instrument facilitates moisture retention, leading to oxidation and localized corrosion. At our Lowton facility, we utilize ultrasonic cleaning to remove calcium carbonate deposits that compromise internal diameter tolerances and disrupt laminar airflow, ensuring the bore remains within specified mechanical limits.
Precise valve alignment is critical for acoustic efficiency and back-pressure regulation. We utilize professional-grade measuring tools at our workshop, which serves clients from Widnes, to verify that piston ports align exactly with the casing apertures. Misalignment by as little as 0.5mm creates internal turbulence, affecting the pitch center of the flugel horn. Our repair protocol involves precision valve lapping using specific abrasives to restore a vacuum-tight seal, ensuring the mechanical action remains responsive and the compression levels meet factory specifications.
Structural repairs involve the extraction of dents from the leadpipe and bell sections using steel mandrels and burnishing tools to maintain the original acoustic taper. Maintaining the integrity of the venturi is essential for the instrument’s slotting capabilities across all registers. For instruments where the base metal has suffered significant dezincification, acquiring a new flugel horn from Elliott Brass provides a reliable alternative with modern manufacturing tolerances and consistent wall thickness.
Our workshop in Lowton specializes in the technical restoration of brass instruments, employing precision engineering techniques to maintain acoustic and mechanical integrity.
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Brass Toff & Elliott Brass
The Workshop, 16 Kenilworth Road, Lowton, WA3 2AZ
Call: 01942 702928 | 07810 712992
Serving Widnes and the UK.