Workshop...

Cutting the Keys Apart

The entire keyboard is carefully drawn onto a basswood keyboard blank. The position of the balance rail and back rail pins are indicated on the blank, and a strip of arcades is glued to its front edge. Most important - the keys are numbered so they may be put back together in the right order after the individual keys are cut apart. The blank is taken to the bandsaw where it is cut into groups of three and groups of four keys. Then, using the bandsaw and a scroll saw, the keys are carefully cut apart. This photo shows a group of four keys being separated from one another. When the keys are cut apart, the arcades in the front of each natural key are automatically cut along with them. After a good sanding to eliminate the bandsaw marks, the keys are individually fitted to their pins on the keyframe.