Tech/maintenance My new "DIY" pads...

DavidUK · Apr 18, 2025

Well it started out as "Hmmm... I can't figure out all the faff with shellac and manipulation of traditional pads, must be a way an owner can sort their own re-pad?" The simple bit is the ease of one-time installation of the magnets and the self-levelling pads. The tricky bit is for the average Joe to understand the mechanics of a standard horn, the inter-relationship of moving parts, getting tone holrles level, and how to do a basic setup.
So yes, you're right, it does require a level of skill to do that. But then a tech has to be trained in traditional pad installation and can make mistakes whatever pad type. But DIY?... perhaps not.

Eulipion2 · Apr 18, 2025

I'd like to counter with, most horn repair is going to go over better in the hands of a competent tech than a rank novice, but with practice comes competence. There are several folks who do very good work on their own horns, and for whom DIY is a necessity. I'm in a bit of a desert as far as techs go, and finding someone who would be willing to install these for me would be quite difficult.

As for *what quality of techs* are available to me, I've been waiting three weeks so far for a simple tenon fitting!

Speaking for motivated DIYers, please don't give up on us yet!

*Edited for clarity

Woodpad · Apr 18, 2025

Eulipion2 said:
Speaking for motivated DIYers, please don't give up on us yet!

It just a fun challenge to reach .01mm accuracy with 0.1mm equipment.

DavidUK · Apr 18, 2025

Woodpad said:
It just a fun challenge to reach .01mm accuracy with 0.1mm equipment.

Speaking of which, my pressed in threaded rivet bush pad centres dispense with the previous nut and shims for pad height adjustment.
After many tests of different threadlock fluids I think I have the right solution so each pad can be infinitesimally height adjusted by simply turning the allen headed mounting screw, left for a few days to settle, adjusted some more if necessary, and then locked into final position.
If needs be the low strength threadlocker can be broken and the screw removed or readjusted with hand tools any time afterwards.

DavidUK · May 12, 2025

Another tune from Drew Stansall, this time on my Yamaha Vito tenor which I recently overhauled with my pads...

View: https://youtu.be/-fgyIMhVjsQ?si=4bWVAU8zwtNu4IkD

DavidUK · Jul 18, 2025

Yes, I have been a little quiet on here...
Moved house last week to the beautiful Vale of Evesham; an ongoing legal battle with our 2023 house buyers who pulled out on the day of completion; and a poorly relative. All have taken a toll on my pad work.
But the pads are all sorted, done, working, finished, trademarked. Oh sure there will be ongoing improvements but I have stocks for 50 horns right now... just no time to re-pad the handful of my own horns I've been looking forward to fitting them to. That will all have to wait for life to settle down a little.
Ho hum...

Trigger · Jul 18, 2025

Hope you like asparagus Evesham is famous for it

Jeanette · Jul 21, 2025

Nice part of the world. Happy new home

Jx

PigSquealer · Jul 22, 2025

Trigger said:
Hope you like asparagus Evesham is famous for it

Really ? I’m putting my house up for sale and moving !

lig · Oct 5, 2025

Just discovering this innovative approach. A little while back I was gifted a student horn that is kind of playable but could use a repad.

Might be fun to attempt a DiY repad with this system. 🙂

DavidUK · Oct 5, 2025

Well... depends how good a DIY tech you are? Only two sets have been released into the wild via a retailer who installed them, as I mentioned earlier in the thread.
I asked the owner recently, after many teething troubles with his MkVI tenor due to misunderstood or poorly explained installation instructions by me to the tech: "Question... would you now choose Pisoni leather or David's self-levelling... knowing what you now know?"
His reply:

"Hi David, I see no difference in performance between your system and the conventional leather pad set up. Clearly they have certain similarities, in that they have to be installed correctly. Where they score highly is that they can be tweaked and replaced with consummate ease by anyone with a modicum of technical ability. The longevity of the pads, I guess, is yet to be determined but if spares are available then this might not even be an issue, subject to cost of course. The opportunity to keep ones instruments out of the hands of unscrupulous and incompetent repairers can only be welcomed and could possibly remove some of the mystique of saxophone maintenance and regulation for the player.
Other than sorting out a few teething problems I can see no downside to having your pads fitted to my saxophones; I am more than happy with the upgrade. ☹"

I'm still working on the new house rather than this project but a few more innovations have been spawned from the two "guinea pig" horns which were re-padded 10 months ago.
Once back on track it would probably take me a few months to finalise the pads, including the needed instructional installation videos.

lig · Oct 5, 2025

@DavidUK - I am a total hack.

Good to learn there will be instructional videos because pretty much any project I start begins with a search on YouTube. 😀

I initially wanted the horn to disassemble and either get painted some wild funky color scheme or perhaps have vinyl wrapped for shows that where such an axe would be appropriate.

Luckily for me I have an excellent tech for my "real" horns so I won't be endangering any of them with my ham fisted attempt at padding.

I see this as an adjunct kind of thing for my use case. Pads that need more frequent replacement/attention like the palm keys, G# or Eb would benefit from an easy, quick change capability.

Eulipion2 · Oct 6, 2025

Man, I've been enthusiastic about this project since the start, and my enthusiasm hasn't waned in the slightest! I have a few different horns that I think would really benefit from having these installed. Good luck with the new house, and good luck with the pads!

DavidUK · Oct 6, 2025

For info, two extra innovations, one tested, one not, are:

1/ Double sided pads. Each backing disc has a firm pad one side and a soft pad the other. Firm preferred but soft copes with slightly uneven tone hole rims. Remove pad (5 seconds). Remove centre screw and reflector if fitted (10 seconds). Flip disc over and replace screw, with recommended thread locker (30 seconds). Replace pad, close key (15 seconds). Play. Tested and works great.

2/ PTFE coated pads. Food safe dry coating. Dry coating avoids dirt/dust/debris adhering. PTFE coating minimises sticky G# etc. or longer term storage stickies. To be tested.