Key Lead Press by Dana Mazzaglia 2024-06

This experience is totally personal. The methods are yet to be improved. Thanks to our big boss for teaching us this process. Gratitude to Dana, the tool maker. Texting, in my mind, to Mr. David Betts wherever he is, maybe fly fishing in Vermont?

A little less than a year ago, we started to try out key lead press made my Dana Mazzaglia. He is currently an engineer at Mason & Hamlin piano factory. In the first picture, the left is his press, the right is a traditional press. Dana's press requires the key lead holes be drilled though. The traditional one wants the hole not drilled through, leaving a thin wood for backing when leads are pressed in. You can see that Dana's design has a support on the bottom to help squeeze the lead into the wood, key stick here.

To drill a through hole, first, set up the drilling depth so the first drilling is not a through one, yet leaving a dent on the other side on wood. Turn the key over, aim the bottom tip of the forstner bit to the dent, drill in. You'll hear the wood cracks when the two holes on both sides meet and become one.

Use anything on hand to poke out the wood in the hole. Keep drilling on both sides until all keys are processed. The last picture shows what happens if not doing the double drilling on both sides of wood. The wood chips seriously at the bottom of the hole, very ugly. 

Place leads in the drilled holes. Make sure the front weight is as designed. Press leads firmly into the key sticks. Note the three circles on each lead. It is an attempt to press on the edge of lead to squeeze it into the wood. When all leads are pressed in on one key, tap the key on a soft surface to check is any lead is loose. Keep going till all keys are leaded.

Again, notice the bottom support on the press. It helps squeeze the lead into the wood. You don't need to press very hard, or the wood may crack. This method results in nice looking key sticks with minimum cracks on the wood compare to the traditional way where the lead holes are not drilled through.

Yes, Mr. Reveley, the shop owner, melts his own lead for quality control and surely or maybe for fun, as well. He does all action design at Absolute Piano and help technicians who are interested.