I was able to pick the brain of Mark Metzler (http://www.metzlerbrassrepair.com/), who has been an invaluable resource working on these antique horns in the past. Since I didn't have an original leadpipe work from, he provided some advice, like the fact that the tubing in the leadpipe would be cylindrical, not conical. He also on gave some tips on determining the right length and diameter of tubing to use, but ultimately I had to do a bit of trial and error work, mocking up parts held together with teflon tape, testing the instrument and taking notes to come up with the right dimensions. I found a little help from the website for Olde Towne Brass, a period brass band that lists many of the instruments in their inventory along with pictures. They have an identical instrument by the same maker (Hall and Quinby) with the original leadpipe. Looking at their photos provided a starting point for determining the length of tubing needed. I tried several different pieces of tubing, and ended up using a piece of the cross-brace from a trombone handslide cut to length. The diameter was just right, and the finish even matched the rest of the instrument.
The receiver on the instrument had the same taper as a trumpet mouthpiece receiver, so I was able to cut and drill out the shank of a trumpet mouthpiece to make that end of the leadpipe.
 |
| The shank of a trumpet mouthpiece, held in a scrap receiver taken from a junk trumpet, is held in the lathe ready to be drilled out to match the bore of the leadpipe tube. The front end was then drilled out further so that the leadpipe tube could slide in and be soldered in place.
The owner wanted the mouthpiece end of the leadpipe to accept a modern cornet mouthpiece, so I was able to put a generic cornet receiever there. With everything soldered up and buffed, the final product looked pretty good.
Well, maybe a little too shiny, but time will take care of that.
 |
