I design and cut my combs using a CNC mill. This is just a few seconds of one of my CNC mills in action. Here I am cutting a single test comb.
My Dark combs™ are made from a material that is very dense. I need to spray water onto the endmill to keep things cool.
Once cut, I finish, flatten and check each comb by hand myself to ensure it is up to spec so as to provide best performance and outstanding tone. I do not tolerate any air leak. I fix it before it leaves my workbench.
This is part of a series of checklists I am making available to you.
Click the "Printer-friendly version" link at the bottom of the page and feel free to print out as many copies as you like!
Reed replacement checklist
___ Reed removal pin
___ Reed removal spine
___ Brick or anvil
___ M1.4 tap
___ M1.4 screws
___ Reed wrench
___ Flush cut pliers
___ Drill press or Rotary tool with reamer bit
Remove bad reed
___ Identify bad reed
___ Place correct rivet head into reed removal spine hole (reed tip points away from spine)
___ Punch out rivet
___ Flip reed plate around and place on flat part of reed removal spine
___ Flatten hole using flattening pin
___ Tap hole using M1.4 tap. De-burr as needed
Prepare new reed
___ Obtain new reed
___ Enlarge rivet hole using drill press (1/16th inch bit) or rotary tool with reamer
___ De-burr as needed
___ Flatten rivet pad using flattening tool and flat part of reed removal spine
Install new reed
___ Position new reed into slot standing up and pinch it with your fingers
___ Insert M1.4 screw and tighten all the way
___ Loosen the screw very slightly
___ Look at a light source through the slot and align the reed
___ If the reed doesn't align, remove the screw, enlarge the hole in the rivet pad and repeat all the steps to prepare the reed
___ Pinch the base of the reed very tightly to hold the reed in place and tighten the screw
___ Re-confirm reed position and alignment
___ Snip off back of screw
___ Re-confirm tightening of screw
___ Re-align reed
___ Flat sand draw reed plate or sand down tip of screw in blow plate
Fix reed shape and tuning
___ Correct reed curve using pressure and counterpressure
___ Tune reed