Anatomy of an Overhaul

First, the horn is disassembled. Lacquered horns are stripped of thier finish. All horns are then cleaned in an UltraSonic tank. Using an UltraSonic tank safely cleans the horns. They come out of the tank clean as a whistle without having to use harsh acids.

Next, any parts that need to be removed to make dents reachable are unsoldered. Then the dents are removed from the horn. Above the dents from a french horn bell and a sousaphone bell are being removed on the dent machine. Also, at this time, all valves, slides, and other parts get any attention they need. In the picture on the right, we are honing a trumpet valve.

The horn then is buffed by our veteran buffer to remove scratches. In the pictures above, Fred is buffing a sousaphone and a trumpet bell and Chris is buffing a tuba bell.

The horn is remounted and any parts that need replacing are replaced at this time. Pictured above, Dwight is remounting, or soldering, a trumpet and a tuba.

The buffer cleans up the solder joints and polishes the horn to a mirror like shine. Above, Fred is ragging a sousaphone and Chris is ragging a tuba. Parts that cannot be reached by the buffing wheel are "ragged."

Next, the horn goes through a three stage cleaning and degreasing process to prepare it for finishing.

Depending on what you specify, the horn is either plated, with silver or gold, or it is sprayed with high quality baked epoxy lacquer. After spraying, your instrument will spend thirty minutes in our oven at 375°. Here, you can see Dwight spraying a trumpet.

The horn is reassembled with new felts, corks, and high quality lubricants. Finally, it is play tested to be sure the instrument meets even the most discriminating players standards.