Saxophones Case refurbishment

I did this case renovation a while back. A few pictures posted here and there but nothing of the complete build.
Sometimes there are no options for a aftermarket replacement case. So this is what happens when you try to restore what you have. It’s very time consuming but in this case (pun intended )worth it.

This is a case to a 1933-ish H. Bettoney metal clarinet. Initial inspection it looked like it just needed a few spots of glue.

I’ve never done a complete overhaul of a case before. Previously I’ve had some success relining the interior of a flute case.

I’ve had extensive formal training in cabinet furniture/Millworks. Originally the trade I planned my future for. Things change. This project is well within my comfort zone. I actually started to giggle because this was just stupid. I’m only doing this because I can and need the case. I already know this is going to be 50 hours of work.

 

[PigSquealer]

Missing foot ? No big deal to make one. I have three other samples to choose from. If you do this just make sure they’re symmetrical.

I lightly brushed the surface with some WD-40 as a mold release. Using hotmelt glue I covered the piece for my casting.

Let cool well.

 

[PigSquealer]

Casting the part using JB Weld. Mix 1:1 and pour into leveled casting. Don’t forget a gentle brushing of WD-40 inside the casting.

Let cure 24 hours.

Sand/file and shape to fit.

 

[PigSquealer]

I marked out the area where the foot belongs. Hope I’m correct. I coded the surface area and the bottom of the part. Don’t flinch sticking it on. You’ve got one shot !

A quick masking job and time to give it a squirt of paint. Plastic specific textured paints are available. Not adding another $15 to the repair. I bought a box of these paints from an estate sale. Two dollars for a dozen.

The next owner can do the upgrade if they wish. It’s clean and solid and that’s all that matters to me….Good-N-nuff !

 

[PigSquealer]

For anyone interested. I did a repair thread on the saxophone itself.

https://www.saxontheweb.net/threads/martin-indiana-alto-diy-full-repad-service.395436/

 

[Jeanette]

Brilliant job. I hate waste. It must be so satisfying to get this kind of result 🙂

Jx

 

[PigSquealer]

Brilliant job. I hate waste. It must be so satisfying to get this kind of result 🙂

Jx

Thank you!
I’ve never been one to be wasteful. Many things get tossed in the bin due to economics. I could have easily gone out and spent $100 or more on a new/used case. I used maybe $25 /£20 on materials at the most and maybe 3 to 3 1/2 hours of my time. I try to encourage and inform those willing to do DIY repairs. Trying to make money on this as a technician is a complete loser. Largely the reason they go in the bin.

 

[lydian]

Beautiful job. Very clever solution on the missing foot too.

 

[Dale.]

Excellent job m8, tell me does the interior smell of the added product
for a while? Or does air drying sort that out.
Dale

 

[PigSquealer]

Excellent job m8, tell me does the interior smell of the added product
for a while? Or does air drying sort that out.
Dale

The shampoo has a short lived fragrance. The glue has none. Body filler smells like fiberglass resins. All but gone in a week. About the same for the new paint smell. Leaving a case in fresh air open matters.

 

[Dale.]

Thanks for the quick reply, all the best.
Dale

 

[PigSquealer]

That finished color was really bugging me. I was at the hardware store picking up some supplies for the house. They had the plastic paint in a better color. No texture paint available. They don’t carry it. $7 upgrade.
Lightly sanded to help it stick. Masked off and gave it a quick squirt.

Compared to the old color!

 

[PigSquealer]

View attachment 21182

Not done 🙁 I just realized I forgot the name badge. Have to go looking for it.

I have pads for the noise maker. Should I ?

Still looking😳

Well 13+ months later I’ve found the case badge. One little 90 years old foil sticker completes the job. Now it’s done.

 

[Ivan]

Well 13+ months later I’ve found the case badge. One little 90 years old foil sticker...

... For the cost of a new case?

 

[murrayatuptown]

I am glad you said 50 hours early in the story.

I hate the musty-mildew-y smell of cases. I bought an obscure Keilwerth stencil alto sax in need of repairs, had it overhauled & tech didn't mind the smell. I smell it on the horn when I pull it out of the case so the case was condemned.

I tried to buy a used case, and apparently Keilwerth's are a little longer and it wouldn't fit anything they had lying around. Kind of irked me to have to buy a new case in a style I didn't want. Glad I didn't toss it i the dumpster at the shop, because the neck was still in the case!

I had a change of heart & saved the little stinker (case). It was either a Cheney from UK, or its hinges were made by Cheney. Probably the whole thing, not just the hinges.

I thought 'how hard' can it be to gut it, replace the foam blocks & fabric?

Oh, the gold fleece was only $6 or so? Almost enough to make me forget about that 50 hour warning.

I saw a KW road case from Japan on eBaY for USD1200! Probably smells like someone else's flavor of trans-Pacific mildew, anyway. No thanks.

Maybe I'll just have to get used to the new gig bag with the zippers. It's already begrudgingly paid for. If I fix the stinking case, I'll have a spare empty case taking up space I don't have.

The challenges of life...

 

[ghostler]

I saw a KW road case from Japan on eBaY for USD1200! Probably smells like someone else's flavor of trans-Pacific mildew, anyway. No thanks.

For that cost, you could simply buy this bari for $1,285.99 US with free shipping. Then sell the bari and keep the case.
Amazon: Mendini by Cecilio Low A Baritone Saxophone

But seriously, would this $240 US case suffice?
Sweetwater: Protec PB311CT Pro Pac Baritone Saxophone Case

This graphic gives case dimensions:

Image from Baritone Saxophone Case - PRO PAC, Bb & A

I have 2 Protec cases, one for my Vito tenor, other for my Venus straight soprano. They are reasonably stout, of better quality than the flimsy zippered cloth covered moulded foam cases on budget Oriental saxes.

 

[PigSquealer]

@murrayatuptown , 50 hours was probably on the short side.
1) If the factory case is structurally solid. Carefully gut the thing. Retain the parts for working replication. Scrape the interior the best you can. Sand the surfaces with a mask on. Brush apply a clear well thinned lacquer or sanding sealer to the interior. The wood retains a lot of the smell. Reupholster with modern materials and upgrades.
2) options,
Is this a split bell model ?
Have the length, width & height measurements. Approximate year/ model.
Contact customer service at current case makers.

Pre 2020 list but may be helpful.

Dropbox

www.dropbox.com

 

[ghostler]

@murrayatuptown , 50 hours was probably on the short side.

An on-line search puts musical instrument repair technicians at $20 to $50 per hour. That does not include overhead, burden and profit. But, it can help someone who using his labour rate at work to figure what his time is worth at home.

At the lowest, 50 hours x $20 = $1,000.
At the highest, 50 hours x $50 = $2,500.

Now when the Mrs. wants her nails and hair done, it is a lot easier to hand her your billfold.

Could it been a $20 tech that badly scratched an alto sax neck to replace the mouthpiece cork? 😉

Café: Best Lacquer Finish to Get?

 

[skeller047]

An on-line search puts musical instrument repair technicians at $20 to $50 per hour. That does not include overhead, burden and profit. But, it can help someone who using his labour rate at work to figure what his time is worth at home.

At the lowest, 50 hours x $20 = $1,000.
At the highest, 50 hours x $50 = $2,500.

Now when the Mrs. wants her nails and hair done, it is a lot easier to hand her your billfold.

Could it been a $20 tech that badly scratched an alto sax neck to replace the mouthpiece cork? 😉

Café: Best Lacquer Finish to Get?

Ten years ago a tech told me that he liked to get $100 an hour. Of course he is a great tech and owns the business (Lee Kramka of Lee's Sax Worx in San Francisco), but I think those numbers are way off. I think Lee's standard overhaul is now at about $2000. Maybe more.

It was $1500 ten years ago. Tenor still plays great. So that's $150 per year... might be time for a tune up...

 

[ghostler]

Ten years ago a tech told me that he liked to get $100 an hour.

Yes, that is with overhead (mortgage/rent, utilities, insurance, advertising, security, vehicle(s), tools, furnishings, bench stock, storage, taxes on those, etc.), burden (taxes on labour, health insurance, pension, holidays, etc.) and profit, all amortised.

Of course he is a great tech and owns the business (Lee Kramka of Lee's Sax Worx in San Francisco), but I think those numbers are way off. I think Lee's standard overhaul is now at about $2000. Maybe more. It was $1500 ten years ago. Tenor still plays great. So that's $150 per year... might be time for a tune up...

Your "amortised costs" for the practical duration illustrates that such costs are justified. Plus performing professionally for a living, ensures that you are able to perform your best on stage.

It illustrates proper perspective. This sometimes the layman musician does not understand.

 

[murrayatuptown]

For that cost, you could simply buy this bari for $1,285.99 US with free shipping. Then sell the bari and keep the case.
Amazon: Mendini by Cecilio Low A Baritone Saxophone

But seriously, would this $240 US case suffice?
Sweetwater: Protec PB311CT Pro Pac Baritone Saxophone Case

This graphic gives case dimensions:

Image from Baritone Saxophone Case - PRO PAC, Bb & A

I have 2 Protec cases, one for my Vito tenor, other for my Venus straight soprano. They are reasonably stout, of better quality than the flimsy zippered cloth covered moulded foam cases on budget Oriental saxes.

Well, my alto will easily fit in that case ;O). I bought some bari mouthpieces through Syos 'Freaks' sale, but don't have a bari yet...not sure I want to wrestle one yet...maybe I should test-drive or rent one.

Just seeing an estimate of time is helpful for someone with poor time-management skills...that's time I could, or should be spending elsewhere, everywhere else.

I have another horn to pick up from an overhaul about 50 km from home, and it's been -10 to -15 C here with snow getting deeper. USPS canceled a delivery today, claiming my street was inaccessible. I think they were running so late by late afternoon they rescheduled. Two other appts. tomorrow have been cancelled due to another storm warning...so the other horn will have to wait.

I have two other string instrument case projects (adjust position of an accessory compartment, and add add'l material to make a deliberately-purchased oversized case fit an odd instrument) - these are unavoidable projects, so that may get me comfortable with transforming a sax case...

Thank you for the help.