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March 22, 2006
Nail in the flute
I had a not so average repair today. Usually, it's binding a crack or replacing an utaguchi. Sometimes I'll refurbish cracked Ji inside a bore or adjust some tuning like moving a finger hole.
This repair started out like any other crack repair. The owner of this flute, who happens to hold the largest collection of shakuhachi in the USA, identified the leak below this rattan inlay.
I thought it would be a simple refurbishing - take the old one out, clean it up, reglue, rebind and wrap the inlay. But upon removing the rattan, I discovered something else.
I'm always careful when removing the rattan because I need to take note of what is happening when starting the work. You never know what you might find, or, what may happen during the repair. Some of you may have followed my Inoue Shigemi repair a while back (that flute was like a time bomb that was set to go off as soon as it came into my hand). The fact that there was no visible crack on the surface of the bamboo near this binding made me suspect something.
I save a lot of old rattan in case I ever have to match rattan.
The thread below the cracked Ji was visible. Not a good sign.
The Ji was in typical shape on this kind of repair, crumbly. My custom made file (from a stack of hack saw blades) hardly moved and the dust began to fall.
To my surprise, I saw a nail. Then I knew exactly what I stumbled upon - a joinery job that came apart.
This kind of joinery is done when makers need to adjust the length of the bamboo.
I applied CA glue to the joint and applied pressure from both ends with a theaded rod.
Then I drilled two pilot holes for a new U nail. You risk cracking the flute if you don't use pilot holes.
After I drove it in flush, I sealed the joint with CA glue and bamboo dust along the perimeter to ensure a good seal.
I have a tin of sifted bamboo dust for situations like this.
Once the glue dried, I filed it down flush.
But before I put on the binding, I needed to make sure there was no leakage so I assembled the flute to see if Ro sang. Here's my favorite joint grease.
A nice gigantic Ro filled the room so I proceeded with the repair by binding it in smoked color 20lbs monofilament line.
After I smeared the entire thing in CA glue and allowed time to dry, I filled the recessed channel with 5 minute epoxy. I'm pretty sure this will last longer than Ji. It's supposed to hold 2,5000 pounds per square inch.
I start with a light file on the top just to remove the bumps.
Next, I use sand paper with both hands to bring it down evenly.
Everything has to be smooth and uniform, Bumps and uneveness will show up once the rattan goes on.
The rattan wrap.
Here's where the old rattan comes in handy.
It broke when I was removing it so it's a shorter piece. But joining it togther in the wrap is quite easy.
Just a little steel wool to clean it up.
Can you see where it was joined?
A beautiful flute once again.
Time for a good night sleep.
Namaste, Perry
Posted by Perry Yung at March 22, 2006 01:09 AM
Comments
Hi Perry:
The file you made of hack saw blades is an outstanding idea. I have often used a single blade for filing.
Although I am not certain if water proofing is a main concern in your epoxy repair, I just want to mention that 2 Ton Epoxy is waterproof and as we know, 5 Minute Epoxt is just water resistant. The drying time is much longer but it is a superior resin in many ways.
Thank you for sharing your fascinating flute world with us, and thank you very much for making such an inspiring Shakahachi that I play during and after my morning meditations. Like walking meditation, I play the flute which brings the practise into the world from the Zendo and helps bring my meditation into my day.
In Gassho, Scott
Posted by: Scott Siken at March 23, 2006 02:25 AM
Hi Scott, Great to hear from you! Thanks for visiting my world of shakuhachi. If I remember correctly, you have a loft in Tribeca?
Posted by: Perry Yung at March 27, 2006 11:09 PM
This difficult repair of a long, special large-hole John Neptune flute is a very good example of the inventiveness and dedication to craftsmanship that Perry shows in his repair work and flutemaking.
All the best,
Chris
Posted by: Chris Moran at April 3, 2006 11:02 PM
Hi Chris, Thanks for your comment. I'm fortunate to be able to work in something I love. Repairs are always exciting, regardless of the quality of shakuhachi. Bamboo flutes are unique and I enjoy meeting each and everyone of them.
Best, Perry
Posted by: Perry Yung at April 6, 2006 01:21 PM
Great photos of an astounding process, Perry! This is my first visit to your site, and I'll certainly be back. I really need to learn more about shakuhachi-specific construction and repair techniques. Thanks...
Posted by: Romy B. at April 14, 2006 02:15 AM
Hi Romy,
Thanks for the visit. Feel free to drop me an email anytime. I used to say give me a ring but these days my time is completely unpredictable. My wife and I have two in diapers. My days are a mix of the playground, toilet training, naps and feedings.
All the best, Perry
Posted by: Perry Yung at April 14, 2006 07:23 PM