Body Fabrication

Photos : Yuichiro Maki
Material
Material • Different combinations of metals are used depending on the model of saxophone.

Body Tube Welding
• A single brass sheet is welded into the body tube component of the saxophone by an automated machine. Welding

Bell Welding
Welding • Each metal is treated differently in the bell welding process, so a craftsman does this step by hand to ensure a consistent finish.

Bell Shaping
• The bell is smoothed and shaped by hand. Bell contraction

Tone hole drilling and pulling
Tone hole processing • Elliptical holes are drilled into the body tube of the saxophone so that a metal ball can be pulled through to create the tone hole.

Tone hole finishing
• The tone hole is shaved down to ensure proper height. Tone hole processing

Key making

 
Press
Press • Manufacturing of the keys begins with placing the metal into a machine that applies pressure down onto the metal and forms the key shape.
  Press

Parts
Parts • There are as many as 300 different parts that have to be made to complete our different saxophones.

Soldering
• The different portions of the keys (cup, arm, rod, etc…) are soldered together with silver. Welding
Welding  
Pads and Corks
Pad, Cork • The pad and the cork are attached to the keys and sprayed with lacquer.
  Pad, Cork

Initial Assembly

 
Post Attachment
Attachment • The posts are soldered onto a metal rib that is then attached to the body of the saxophone.

Surface Processing

 
Buffing
Buff polishing • After the posts are attached each component of the saxophone has to be buffed multiple times – each time using a softer buffer.
Buff polishing Buff polishing
  Buff polishing

Lacquering Process
Lacquer blowing attachment • After the buffing is complete, each portion of the saxophone has to be cleaned using various chemicals and ultrasonic waves.
• The lacquer is then sprayed onto all portions of the saxophone (including keys) and heated in a 120 degree oven. Lacquer blowing attachment

Final Assembly

 
Bell Soldering
• The bell and bow are soldered to the body tube. Attachment
Keys
Attachment • The keys and springs are then attached to the posts. There are about 15 different people involved in this process.

Hand Engraving
• Each saxophone is skillfully engraved with one of our 5 artists. This process takes place at different times depending on the type of saxophone. Attachment
Inspection
Inspection • A light is used to make sure that each pad is seated properly and that the spring tension is correct through-out the saxophone.

Shipment
• The musical instruments are shipped after wiping and packing carefully. Shipment

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