Caster repair

[Roger Jolly]

At 11:46 PM 9/28/2006, you wrote:
>Thanks, Roger.
>I had wondered, if a 3" would do it, when I was thinking of using a hole saw.
>John M. Ross
>Windsor, Nova Scotia, Canada

Hi John,
                The 3" works well in most cases, and gives a nice clean 
result.  You may have to take some extra material from the bottom of the 
hole  to allow for the extra height of the casters, to correct the pedal 
height.  This will give a clean flat surface to mount the new flange on 
virgin wood.
In some cases we have had to  increase the depth of the shaft hole. I don't 
like those cardboard shims as it raises the height of the piano, and leads 
to pedal complaints.  They also compress and the caster becomes loose.
When the shaft hole is too wide in Diameter, we drill them out in a similar 
manner, and plug them with 1'1/2" dowel.   Glue the dowel in with 5min 
epoxy. Re drill to the correct size for a snug fit. If the supply house 
plugs fit, you are ahead of the game, but glue them in. The shaft needs to 
be snug
Drill out and plug the old screw holes,  Drill pilot holes for new screws 
in a clean area of wood. A note on mounting screws. They need to be wide 
enough that they fill the flange mounting holes.
   The end result will be a good solid mounting that will stand up in 
School use.  Well! As good as anything stands up in a school situation.
The advantage of a Forsner bit over a hole saw.  You end up with a clean 
flat base to mount the flange.
I know.  Forsner bits are expensive.  This is one time a canny Scotsman 
needs to splurge. :-\
Charge a little extra and do the job right.

Regards Roger
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