Brun Part 5: Bellows

The fifth instalment in the story of building my first concertina is about the bellows. First I had to make a new, rectangular mould to assemble them on. The stock for the forms was constructed from strips of softwood glued across a plywood base, which I then ripped into four pieces.

I again milled the forms to shape on the CNC mill. One thing I did differently this time was to rough them out in staircase form with an ordinary ¼” end mill first before cleaning them up with the large V bit.

When I made the forms for the hexagonal mould, I cut straight into the material with the V bit using lots of shallow passes, which caused lots of noise and vibration, resulting in a poor surface finish. Removing most of the material with an end mill first gave much better results.

The wide forms stretched the machine to the absolute limit of its Y axis capacity.

The bandsaw I had at the time wasn’t capable of ripping the angles off the undersides of the forms, and I don’t own a table saw, so I did them with a hand rip saw instead.

The rectangular core was relatively simple to make compared to the previous hexagonal one.

I split both of the long sides to make the mould easy to remove from the finished bellows.

Cutting the cards by hand with a craft knife. I hate this part; it makes my knife hand ache for days afterwards. Also, because this set of bellows was meant to be relatively heavy-duty for a ‘travel’ instrument, I chose to use thicker 1.5mm card rather than the standard 1mm stuff I used on the tuning bellows (in hindsight this may not have been a good idea because it made the bellows a bit bulkier). I have since bought a special card cutting guillotine that in the future will make this operation much quicker and easier.

Rounding the corners of the cards with a gouge. I started off pressing down onto the bench, but I found it was easier to put a cutting board in the vice and lean against the gouge handle with my hip.

I rounded the tops of the cards on a linisher (bench mounted belt sander) with an 80 grit belt. In hindsight I should have done this outdoors because everything in the garage including my car wound up covered in a thick coating of fine grey dust!

The rounded top of a card. This gives a nice shape to the peaks of the bellows folds, though in hindsight it would have looked better still if I had rounded the pointy corners a bit more.

I decided to try hinging the cards together with a self adhesive linen hinge tape made for bookbinding and other card related crafts. The roll was quite wide so I cut it in half. This picture shows the result of a strength test: the surface of the card ripped off before the glue or the linen failed (and it took quite an excessive amount of force to do so).

I started by hinging the cards together on the inside. The peak hinges can be taped with the cards laying flat, but it’s better to do the valley hinges with each pair of cards in the closed position (or flat but with spacers holding a slight gap between them), otherwise they will later resist closing.

I folded them up and clamped them tightly like this for a couple of days to help the tape glue to really bond well to the cards. Note that the end cards are slightly taller because the end boxes are about ¼” bigger than the bellows. This is partly cosmetic and partly to avoid the bellow peaks touching the table when you put the concertina down.

Next I tied the sets of cards to the mould with plastic coated gardening wire. Elastic bands would probably have been easier but I didn’t have any long enough. Note that the bellows frames aren’t attached to the mould. This wasn’t possible with this instrument because the frames have a divider across them due to the split reed pan design.

I ran the self adhesive linen tape all the way around each peak. This gives a stronger bellows than if you just put small pieces on each corner.

Afterwards I took the full set of cards off the mould and again pressed it tightly for a day or two to help the top hinges stick as well as possible. You can see in this picture what I meant about how it would have looked neater if I had rounded the corners of the cards a bit more.

I needed wider hinge strips on the end cards to attach the bellows to the frames, so I cut those from the ‘Fraynot’ hinge linen from Shepherds bookbinders’ suppliers that I used for all the hinges on my tuning bellows. I cut it on the bias to make it less likely to fray or rip.

Then I glued them on. From this point on, I used hot rabbit-skin glue for everything except the decorative papers.

A brief digression about my experience with the self adhesive hinge linen. In future I’m going to go back to using the Fraynot linen cloth for everything. Although the self adhesive tape worked fine and I don’t think it’s likely to come apart, I found that I much prefer working with the Fraynot and a liquid paste/glue, because if it goes on wonky you can peel it straight off and reposition it, whereas the self adhesive tape sticks instantly and you have to tear the surface of the card to get it off again, then throw away that strip of tape. The tape is surprisingly expensive too, though that’s not my primary consideration. It also had quite a lot of wrinkles in it where the cloth had stuck to itself during manufacturing and the glue is so strong it’s not possible to pull the wrinkle out; sometimes I had to waste a section of it to avoid putting a wrinkled piece on the bellows where it would be visible through the leather. Most importantly, I believe the hinges I get with strips of cloth are noticeably thinner and more supple than with the tape. The difference is fairly subtle when looking at a single hinge, but an entire bellows set with hinges on both sides of the peaks feels relatively stiff and bulky when assembled with the self adhesive tape. Although it’s possible the tape is made from a heavier cloth, I suspect the main difference is in the properties of the glue. I have found that traditional wheat paste doesn’t noticeably stiffen the hinge at all, whereas rabbit glue does stiffen it a little initially but after working it for a while it ‘breaks in’ and becomes supple again. Whatever is on the self-adhesive tape has a rubbery feel to it, and seems to add a bit to the thickness of the hinge too.

I covered the bellows with a nice brown goatskin leather from Hewit, cutting it into strips with an Olfa rotary cutter, which really cuts very nicely, much easier to use than a craft knife.Using my Scharffix 2000 to pare the leather down.

Thanks to a thread on the concertina.net forum, I learned that Israeli-made Personna safety razor blades fit the Scharffix and cut really well, better even than the thicker OEM blades that came with the machine. It’s crucial with this machine to use ultra-sharp blades, otherwise it behaves terribly, stretching and ripping holes in the thin leather.

Checking the thickness of the valley strips.

And gluing them on:

 

Cutting out the gussets with a template and craft knife. This is rather a tedious job; a die tool would make it much quicker.

I use the Sharffix to do as much of the skiving as possible, but the gussets always need a bit of manual cleaning up afterwards with a skiving knife.

Gussets glued on. It proved rather a pain to get the bottom corners to fully stick to the valleys without leaving a little gap. I wound up waiting for them to initially dry, then adding a bit more glue to each gap with a tooth pick and pressing it down with a bone folder until it stayed in position. This is less of a problem with bellows that have more than four sides because you don’t have to stretch the gussets around such a tight angle.

I roughed up the tops of each gusset slightly with sandpaper before gluing the top runs over them.

Cutting more long strips of leather for the top and end runs. It’s a pain when the Scharffix goes wrong in the middle of one of these strips because you need the whole run to be good to avoid having more than one joint.

Top runs glued on.

Next I needed to take the bellows off the mould and attach them to the frames, starting with the hinge linen.

Now the end gussets. This was way more difficult to do neatly without the aid of a mould. It helped to use a stick clamped to the frames to hold them a fixed distance apart.

Finally the end runs. As I mentioned in part three, here’s where I realised I’d made a mistake in not making the bellows frames a tiny bit smaller than the action boxes, in order to hide the edge of the end run. I skived the edge down as close to nothing as I could and tried to get that skived edge flush with the edge of the frame, but it was impossible to get it absolutely perfect, so when I subsequently trimmed the extra off, the edge wasn’t infinitely thin any more so it is possible in places to see a tiny bit of unfinished leather. I recognise I am quite possibly being over-critical of my own work here!

Looking pretty good!

For the decorative papers, I took a sample of the leather down to my local craft shop and looked for a patterned decoupage paper that went well with it. This is what I found. I avoided cutting papers from the area near the bottom that looks dirty (the design is actually printed that way).

I spent a pleasant evening cutting out papers and pasting them on while watching TV programmes in the background.

The finished bellows. I think the papers really go quite well with the leather. Although they were still quite stiff and springy at this stage with a preference for remaining open, I subsequently spent quite a while pressing them and exercising them, and they gradually broke in and became easier to play.

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Brun Part 4: Actions

Part four of the story of how I made my first instrument is about the actions (i.e. the mechanisms that uncover holes and let air through a reed when you press a button).

I made the action boards from birch plywood on the CNC milling machine, which seemed to work pretty well. Although I’m sure high-quality plywood is a good choice for strength and stability, on the next instrument I may try making the action boards from solid wood instead to see if it has a beneficial effect on the tone.

Another thing I will probably do differently next time is to not drill the button peg holes at this stage using CNC. They need to be very accurately aligned with the button holes in the end plates for the buttons to work smoothly, and by doing it this way it took me a lot of fiddling about to get the two boards to line up well enough to avoid the buttons sticking. I think a more accurate way would be to bolt the action boxes together with the action boards inside, then use the pillar drill and spot through the end plate using a drill bit glued into a mandrel that is the same diameter as a button (not my idea: I recently heard about this technique via another maker).

The action boards sit in a rebate in the bottom half of the action boxes. The problems I had with the walls not gluing up perfectly square meant I had to make careful adjustments to the edges of the action boards to get them to fit snugly in the rebates while also accurately aligned with the button holes.

I turned a couple of cylindrical brass dies that mark a circle around each pad hole to help glue the pad in the right place.

Lots of pads.

I made a couple of button guide boards to hold them in the right place while gluing the pads on.

Fitting the cross hole bushes in the buttons (see my earlier article about how I made them) using Bob Tedrow’s method of pulling a strip of cloth through them all, then snipping them apart with scissors:

I cut the lever posts from 1.5mm brass on the CNC mill:

And the levers themselves from 1mm brass:

It took quite a lot of fettling with needle files and emery paper to clean them up. I put the pivot points at the half way points for reasons that made sense on the drawing board, however I have since learned that it is better to put them closer to the button if you can find the space to do so (this causes the pad to lift up by more than the distance the button travels down). In hindsight this may have helped with some of the issues I later had with ciphers because I could have reduced the button height by 0.5mm without compromising the amount of pad opening.


I already wrote about the die I made to thread the grommet ends of the levers, but I have since learned that I get a cleaner, more consistent result from it if I squeeze the tool in a vice instead of hitting it with a hammer.

Before and after forming the threads:

Riveting went fairly smoothly. I only had to redo a couple of them because the pivots tightened up.

The reason for the odd shape of the lever posts is so I could knock them in or pull them back out using a tool with a matching notch cut in it (not my original idea).

The tool has a flaw: because the socket is on an edge of the tool but you hit it in the centre, the force is transmitted to the post off-axis, which tends to cause it to go in at a slight angle. I had to straighten up each post with needle nose pliers after knocking it in. I will probably modify or remake the tool before the next instrument to prevent this happening.

All the levers and buttons installed. Unfortunately I discovered a significant problem at this point. The button ends of the levers were too fat, making them very stiff, especially on the shortest ones.

I didn’t want to pull them all out again, so I instead used a rotary burr and needle files to slim them down in situ, which solved the problem.

Some of the springs.

An action board with all the springs and pads installed. Some of the spring locations proved problematic due to lack of space around the middle row of pads, and I wound up spending quite a bit of time working on getting the button pressure consistent across the instrument while also eliminating ciphers (notes that don’t stop playing when you let go of the button). Most of the ciphers were caused by the end of a lever or part of a spring hitting the underside of the end plate; there was really almost no wasted height inside the boxes.

Adjusting the heights of the buttons to get them consistent is done by bending part of the lever it’s attached to. To make this easier I made a pair of special tools from old screwdrivers to grip the levers in situ.

Overall, I’ve learned that there’s nothing tremendously difficult about building a concertina action, but there are lots of little parts to make and it takes a great deal of patience to assemble and adjust it until it works smoothly, consistently and reliably.

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Reed Pan Router Bit

I’ve spent hours searching for a commercially-made router bit that has the right dimensions to cut the dovetail slots in a traditional reed pan. It needs to be an unusually small diameter, but if you want to be able to cut the top slots after installing the chamber side walls as it was done originally (some of them undercut the walls), it needs to have a disproportionately long ‘neck’ between the cutter and the shank. On the plus side, the slot is quite shallow so the neck doesn’t need to be ridiculously skinny. In the end I decided to make my own.

I started with a piece of 1/4″ silver steel. After putting it in a collet and facing the end, I used the side of a threading tool to turn the tapered section, being careful to produce a sharp corner without significantly reducing the diameter of the base of the cone. I made it just long enough to be able to cut a 2mm deep slot, to avoid weakening the neck section unnecessarily. I set the tool holder over to produce the desired 60° taper:

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Next I extended some more stock from the collet and turned the ‘neck’. On my first attempt, swarf obscured my view of the work and I accidentally retracted the carriage too far to the right and put a groove in the cone area. There was no option but to start again! The second time, I used the tailstock as a right-hand carriage stop to protect the cone.

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The trickiest part of making your own router bit is producing the flutes without a special tool cutter/grinder machine. I cut three helical flutes by hand with a very small triangular saw file, then hardened and tempered it and sharpened the edges with diamond needle files:

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Unfortunately it didn’t work well at all. It splintered the surface badly, then overheated:

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Back to the drawing board. I studied a lot of photos of commercial dovetail router bits on Google Images and came up with a very different two-flute shape. Here’s a quick clip of me filing the relief angles on the second router bit with my saw file (click to stop it after you’ve seen it once, because the Instagram player auto-repeats):

Filing relief angles onto the Mk II reed pan router bit. Quite a ticklish job. #concertinamaker #toolmaking

A video posted by Alex Holden (@alexholdenmaker) on

And this is the finished bit, after heat treatment and sharpening. The thing it’s inserted into is one of my milling machine’s quick change tool holders:

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This photo shows the reason why it needs a long neck (I made it a bit longer than would have been necessary for this Treble English, in case I want to make an instrument with deeper bass reed chambers at some point):

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The second router bit works pretty well. Here’s a clip of it cutting a reed slot in a piece of scrap pine:

Programming the CNC mill to machine the slots is surprisingly complicated. The CAM software I’m using doesn’t understand how to cut a pocket with a tool that can’t plunge straight the workpiece and needs to enter and leave the edge of the material. I found a way to trick it into doing what I need, but the entire process filled nearly two pages of my logbook, and I need to do it all again for every size of frame I need to cut!

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Another problem I ran into is that the outer dimensions of the antique Lachenal reeds I’ve been copying are a bit variable. Not by much, but a tenth of a mm change in width makes the difference between a snug fit and a loose one. This one fits very well – I can throw the block of wood in the air and catch it and the reed is still nicely seated – but the reed taken from the slot next to it (nominally the same frame size) is loose enough that it would fall out. I think when the instrument was built, somebody must have spent a while individually fitting each reed to its slot. Luckily my CNC mill (which I’m using for both the frames and pans) is repeatable to tight enough tolerances that I shouldn’t have this problem.

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Acetal Buttons

I made a batch of buttons for my first prototype instrument. For simplicity I decided to use solid black acetal (an engineering plastic, commonly called Delrin, though that is a trademark of DuPont) rather than metal. Acetal is used by most modern concertina makers and it has a number of useful properties; particularly ease of machining, low mass, low friction, and low thermal conductivity (i.e. they don’t feel cold to the touch). I believe the top quality instruments still tend to use hollow metal buttons though.

The acetal came through the post in 1m lengths protected by a plastic tube. Long lengths of it are quite bendy. I started with 6mm and turned it down to 4.8mm. Before putting it in the lathe I cut it into 250mm lengths, which was about as long as I dared (shorter would result in more wastage, any longer risks the unsupported left hand end whipping around dangerously). I got nine buttons from each length.buttons2

I did most of the work on my manual Taig micro-lathe. I did a few things differently than usual in order to increase efficiency. For instance I set up both a standard right hand tool in the front toolpost and a parting off tool in the back toolpost so I wouldn’t have to mess about changing tools twice per button.

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I made a couple of simple length gauges to control how much of the stock was protruding from the chuck at each stage, then turned up to the Z axis stop (set up to allow the carriage to almost touch the chuck). The short gauge is for the peg on the bottom of the button, and the long gauge is for the main body of the button. I also made full use of the graduations on the cross slide handwheel to produce the two diameters without stopping to measure the part.

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I made a special jig to hold the button while I drilled and countersunk the cross hole on both sides. It is built in such a way that you can turn it over 180 degrees and locate it using the two pins on the baseboard, which is clamped to the drill press table.

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Although this photo shows a standard jobber drill bit, I found it worked better to first use a smaller, more precise drill press to spot the hole location with a small centre drill, otherwise the bit drifts to one side or the other and you end up with an off-centre hole.buttons7

Finishing the top of the button involved facing off the parting-off stub, hand-sanding to round it off slightly, then flame polishing with a pencil torch to get a smooth glossy finish.

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(Close-up picture of the polished button didn’t come out well – it turns out that my camera’s autofocus struggles to lock onto glossy black objects!).

This video shows the whole process:

Here’s a finished button:buttons8

And the full batch (more than I need for the first instrument – I made extra because I wasn’t sure how many I would ruin in the process, and I can always use the extras for my second instrument):

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After completing the buttons, I now had prototypes of all the parts of a concertina action, so I decided to put it all together in a little test piece:

As well as the crude box itself, I made the pad, samper, grommet, lever, post, spring, felt washers, button, and both bushes. It is currently sitting on my desk as an executive toy, and I find myself reaching out and pressing the button whenever I’m thinking about a problem!

Update: After a couple of days of pressing the button whenever I happen to be at my desk, it definitely operates smoother and easier than when I first assembled it. I think the pad may be sealing more tightly too.

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Prototype Action Lever

I made a prototype action lever. It’s a Wheatstone-style riveted lever hand-cut from 1mm thick brass sheet (the post is 1.5mm; possibly a bit thicker than necessary, but I didn’t want it to distort when I hammered it in).

The hardest part was making a die tool to thread the pad end so that I could screw the leather grommet onto it. Because the lever is cut from thin flat sheet rather than round bar, an ordinary thread cutting die wouldn’t have worked, so I instead made a sprung die set to form the thread.

I started with a 15mm x 25mm x 100mm bar of O1 tool steel, drilled and filed a spring shape on one end, then slit it in half:

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Next I clamped it tightly together in a vice, and drilled and tapped an M2 hole in the middle of the slit, near the opposite end to the spring:
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I put a couple of M5 threaded holes in the bottom so I could bolt it to a chunk of angle iron, then hardened and tempered it to 200C, differentially tempering the spring end to a higher temperature with a blowtorch so it won’t break in use:
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After a bit of experimentation, I found that I could get it to form an acceptable thread if I cut a section of the 1mm sheet to 2.5mm wide (this dimension is fairly critical: 2mm forms almost no threads, and 3mm distorts and creases badly). It works best to hammer the tool fairly hard four times: once with the lever vertical, once each at 30 degrees from vertical in both directions, then a final time with the lever vertical again.
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The lever after sawing it out with a jeweller’s saw, forming the thread, and riveting it to the post:
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The proportions were based on one of the shortest levers in a treble English; most of the levers will have longer straight sections. The straight section is 2mm wide; I had to make the threaded part a bit wider (the tool squishes it narrower and thicker):
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After screwing the grommet on. It is necessary to enlarge the hole in the leather grommet to 1.65mm before it will screw on without using excessive force and damaging the grommet:
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Spring Winder

I made a simple machine for winding concertina springs, inspired by Bob Tedrow‘s video.


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It has a drum with a mandrel sized for the desired coil diameter and a hook on the outside, driven by a crank handle. The small step at the base of the mandrel helps to get the first turn of the coil tight. The adjustable guide plate isn’t strictly essential, but it helps a bit with consistency.

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The raw spring material; 22 S.W.G. (about 0.7mm) phosphor bronze spring wire. It bends easily, is fairly corrosion resistant, and I’m told it lasts a lot longer than brass. At some point I’m planning to experiment with stainless spring steel and other diameters, but I’m sure the phosphor bronze is going to work fine for my initial prototype instrument.

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Step 1; use needle nose pliers to bend a right-angle that will form the ‘pin’ that you push into the action board:

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Step 2; insert the wire into the machine as shown. It’s important that the hooked end is parallel to the face of the drum:

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Steps 3 and 4; turn the crank handle clockwise about 2 1/4 times, then cut the wire off, using the guide plate to gauge where to cut.

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Step 5; use small round nose pliers to form the hook:

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Step 6; use needle nose pliers to bend the hook over at a right angle:

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The finished spring:

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Here’s a quick video of the process:

Sometimes it’s necessary to use an opposite-hand spring because of limited space on the action board. You make these in the same way but doing all the bends the other way and turning the crank handle anticlockwise:

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A few experiments with various arm lengths:

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Punching Washers and Grommets

I decided I wanted to try making some punch tooling in order to manufacture a couple of the parts involved in a traditional concertina action: the felt washers that go under the buttons and the leather grommets that screw onto the ends of the action levers.

As well as the big Smart & Brown 2-ton toggle press mentioned previously, I also have a little 600N Brauer one (if my calculations are correct, the big one is rated to deliver about 30 times the force of the little one). I got it second hand some time ago, with some odd custom tooling attached to it that I never figured out what it was supposed to do. Here it is after removing the tooling and cleaning it up a little (yes, that is an old gear knob on the end of the handle – actually quite a nice addition so I left it on):

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Because the throat height of the press is considerably more than the thickness of a piece of felt or leather, I turned up a 50mm tall spacer block from scrap 1″ mild steel bar. It bolts to the table of the press and has an M8 threaded hole in the top for the punch anvil, and a cross hole for the ejection of waste punched through the hole in the middle of the anvil.

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I needed to cleanly bore out the inside of the felt washer punch, so I ground a simple D bit from the 1/4″ shank of a broken HSS end mill:

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I drilled most of the waste out first, then used the D bit to open it out to 1/4″ and cut a flat bottom on the hole. At this stage I also drilled a 1.5mm hole for the centre pin:

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I used the compound slide to turn the tapered sections of the top punches, stopping while the edge was still fairly blunt. After hardening and tempering, I put them back in the lathe and used emery paper to clean up the taper and sharpen the edge.

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Threading the other end of a punch with an M8 die so it can screw into the press arbor:

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The anvil and felt washer punch installed in the press. I made the half-nuts that are used to lock the tool at the desired height by facing ordinary full nuts on an arbor.

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Here’s a quick video clip showing the felt washer punch in use:

This shows where the washers go on the buttons, to stop them making a clacking noise when they bottom out:

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A nice stockpile of washers for my first few instruments. I made these from a sample piece of ‘baize’ woven wool cloth as used on gaming tables. I also have several other sample pieces in various different colours. I think the original washers may have been made from an actual fine, thin felt rather than a woven cloth, though – I need to get hold of some samples to experiment with.

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The first anvil I made had a design flaw: the hole through the middle for the ejection of waste material was drilled 1.5mm diameter all the way through the tool. In practise it quickly became constipated and I had to repeatedly remove it and drill out the waste. The one on the right is a second, improved version that is relieved to a larger diameter until a couple of mm from the top surface:

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Here are all the punches and anvils I made. The first one is the felt washer punch. Inside it is a couple of layers of spongy foam and then a couple of felt washers; with careful adjustment of the pressing force this seems to be just right to prevent the washers getting stuck inside. The second one I had optimistically hoped might work the same way, but the grommets just got stuck inside it and wouldn’t come out, so I instead decided to use it to punch out the centre hole and mark the location of the outside of the grommet, then switch to the third punch which has a slot milled in the side to allow the grommets to be pushed through and removed from the top.

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Here is a video clip showing the leather grommet punches in use. Note that in the video I was using 2.5mm veg tan cowskin, however I subsequently found that I got much better results from 4mm leather instead (the 2.5mm leather compressed down to 1.5mm in the punching process and the 4mm to about 3.2mm). I also removed the stripper plate seen in the video because I found it was getting in the way and causing more trouble than it was worth:

This shows where the leather grommets go inside the instrument. They screw onto the end of the lever arm (which is lightly threaded), then glue to the samper disc on top of the pad:

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A couple of hundred leather grommets for my first few instruments:

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Although these are fairly trivial parts, it certainly feels like progress to be stockpiling significant quantities of production-quality parts that I have made using my own tooling.

UPDATE: I’ve since got hold of some 0.8mm piano bushing cloth and punched more washers from it:

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The piano bushing cloth is thinner, finer, and more tightly woven than the baize. Unfortunately I’ve only been able to find it in bright red with a white core. I may experiment with dyeing some of it black.

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Reed Prototypes Part 1: Frame and Clamp

Recently I made my first prototype concertina reeds. There’s a lot to write about so I’m going to divide it into two articles, this one will cover the frames and clamps, and the next one will cover the tongues.

My plan was to make a drop-in replacement for one of the low ‘B’ reeds in my vintage Lachenal English. I think this instrument was probably one of Lachenal’s higher-end ‘broad scale’ models, because I also have another steel-reeded Lachenal that in many cases has narrower reed tongues in the same pitch. I’m not totally sure why the narrow scale models existed or were originally cheaper than the broad scale equivalent (the extra metal and labour is fairly trivial). They were probably quieter at the top end of the dynamic range, which might make them better for a student instrument.

I understand Wheatstone’s earliest reeds were made totally by hand, piercing them with a jewellers’ saw and cleaning them up with files. This must have been very labour-intensive, highly-skilled work, and prone to inconsistency. At some point fairly early on, perhaps when Louis Lachenal was hired to mechanise production(?), they changed to using fly-presses and dies to punch out the reed frames. This was much faster, worked well, and the presses could be operated by relatively unskilled workers, but the disadvantage is that precision dies are very expensive to make. To save on tooling costs, instead of making a different set of dies for every pitch of reed, they made do with a handful of sizes and made up for the gaps between them through careful tongue profiling. Until relatively recently, the need to invest in a set of press tooling was a significant barrier to entry for new reedmakers.

Enter CNC machining. I understand other makers have successfully used laser cutting or possibly wire EDM, but I have my own small CNC milling machine so that is the process I am going to use. It is fairly slow (certainly compared to a a press tool), but it works pretty well and I hope to get to the stage where I can load in enough brass for half an instrument worth of reed frames, and set it going with minimal supervision while I work on another task. As well as cutting out the shapes of the frames and clamps, it can also cut the vent slots (albeit with filleted corners), drill the clamp holes, engrave the note labels and a logo, counterbore the clamp screw holes, and even chamfer the top edges of the frame so they fit nicely into the dovetailed slots of the reed pan. Initially I’m planning to copy all the dimensions of my prototype reeds from the Lachenal instrument, but in future when I understand the design parameters better I will be able to make frames that are the optimal size for each pitch.

My first attempts at milling frames were using scrap aluminium. It took me quite a few failed attempts before I got one that seemed pretty good (the antique Lachenal frame I was copying is on the right):

aluminium_reed_attempts

Next I moved onto brass prototypes, immediately running into problems with it cutting very badly and breaking 1/16″ end mills:

failed_brass_reed_shoe

A microscope view of an end mill with clogged flutes, from a run that I aborted before it snapped:

clogged_end_mill

I think the reason for my problem was that the chips weren’t clearing from the slots properly so on subsequent passes they were getting re-cut and generating a lot of heat. I experimented with a lot of parameters, but basically what worked was making the depth of cut shallower, increasing the spindle speed to 10K RPM (the maximum my machine’s spindle can handle), significantly increasing the feed rate (to make bigger chips), and adding a compressed air blast to blow the chips away. I also changed from two flute HSS bits to three flute cobalt bits, though I’m not certain that helped with the chip clearance (it did allow me to increase the feed rate a bit more). It also proved necessary to make some proper mechanical clamps to hold the plate to the spoil board, because double-sided tape wasn’t holding it securely enough:

sheet_metal_mill_clamps

Here is a (21 minute long) video of the process of milling a single reed shoe prototype. Don’t bother watching the whole thing unless you’re really fascinated! This isn’t quite the final program: I subsequently altered the bevelling operation slightly so that the frame wedges more securely into the reed pan.

The CNC program includes small tabs that prevent the parts coming loose during machining. Afterwards these need to be manually cut. I found that it was possible to break them out with a small chisel but it left rough stubs that I then had to clean up with a file, so I changed to cutting them with a jeweller’s saw:

cutting_reed_frame_tabs

Because I cut the vents using a 1/16″ end mill, this leaves 1/32″ radius fillets in the corners, which should ideally be dead sharp. I’ve been manually cleaning these up using a fine square needle file with one edge ground smooth. I put the reed frame over the small square hole in my bench peg (see previous photo), hold the safe face of the file flat against the end of the vent, and carefully file sideways into the corner until it’s as sharp as possible without leaving a nick:

reed_vent_squaring

The clamp screws I’m using are a bit smaller than the originals; they are M1.6, stainless steel, with 2.5mm diameter allen heads:

clamp_screw_comparison

In my testing they are strong enough for the purpose and take up less space than the originals, and the finer pitch and allen heads make them easier to tighten and loosen without damaging them.

When tapping the clamp screw holes in the frame, it’s very important to keep the tap perpendicular to the hole. After researching tapping machines and complicated guides, I came up with this simple method that works surprisingly well (though I still managed to break a tap the first time I tried to tap one of the brass shoes!):

I added counterbores to the holes in the clamps because it was easy to do and significantly reduces the height of the reed without weakening the clamping ability. It also improves the accuracy of the location slightly. Because I was already using an engraving operation for the note labels, I added a simple brand to the clamp (HC=Holden Concertinas):

reed_clamp

Because the screws start out a couple of mm too long, I put them in the frame and grind them almost flush with the bottom of the frame, then finish them off with emery paper on a sheet of glass:

grinding_clamp_screws

One of the defining characteristics of traditional concertina reed shoes is that the underside of the vent is relieved (i.e. the bottom of the slot is slightly wider than the top). My current understanding is that this allows the reed to work properly even at very low bellows pressures, i.e. it enables you to play quietly if you want to. It also has an effect on the tone. I’m not doing this on the milling machine because there are good reasons to cut them out from the top and it would be a bit tricky to turn them over and accurately register them for an extra operation. Instead, I made a special jig that allows me to file the vent to a consistent angle using a flat needle file with two safe narrow edges.

The clamp part of the filing jig started out as an old war-surplus hand vice with damaged jaws:

vent_filing_jig_1

vent_filing_jig_2

I trued up the jaws and modified the profile of the front jaw so that there is room for the file to tilt down below the level of the back jaw:

vent_filing_jig_3

Next I added an adjustable brass frame and a PTFE roller to guide the file, as shown in the following video. I align the top edge of the vent with the top of the back jaw, paint the inside of the vent with a black marker pen, and file until I’ve almost but not quite removed all the ink.

Here we have my first brass reed frame in my Lachenal reed pan. You can see how much lower-profile the new screw heads are: I think this might help with air flow inside the reed chambers. It took several prototypes before I was totally happy with the tightness of the fit in the dovetailed slot. There is a small area around the clamp that isn’t fully bevelled, giving a nice friction fit without compressing the sides of the frame adjacent to the vent.

reed_frame_finished

finished_brass_reed_frame

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Tuning Bellows

Recently I’ve been working on making myself a new set of tuning bellows. The first tool I made towards this goal was a new craft knife for cutting leather and card. I ground it from a piece of HSS machine hacksaw blade, because I had read that the steel is more wear-resistant than a simple carbon steel, and I wanted to test the theory.

craftknife

I’m not convinced it holds an edge better than a well-tempered O1 blade, however it does work pretty well. Unfortunately the spalted beech scales (glued on with epoxy resin) popped off after a couple of days. It would have been better to have riveted them on, however drilling holes in hardened HSS is easier said than done. For the time being I have just bound them on with a length of thick elastic.

On a roll with the knife-making, I next made myself a leather skiving/paring knife from the same materials as the craft knife:

skivingknife

This video shows how I use it:

I do of course also have a Schärf-Fix 2000 skiving machine, which I wrote about previously:

The Schärf-Fix is good for long strips, whereas the knife is better for skiving small pieces (particularly gussets) and odd bits here and there. Both tools are tricky to use, and I wasted a frustrating amount of leather while getting to grips with them. The Schärf-Fix has a tendency while edge-skiving a long strip to suddenly dig in and cut a chunk out of the strip. The key is that the blades have to be absurdly sharp, because the thin leather tends to stretch badly if you have to use any significant force to pull it through the machine. I need to spend some more time figuring out a way to resharpen the disposable blades (stropping didn’t help much), or I’ll end up going through at least a couple of them per concertina.

I used my Käfer Dial Thickness Gauge to make sure I was paring it consistently:

I needed to make end frames for my bellows, so I first needed a way to accurately make the corner reinforcing blocks. Here’s the jig I came up with. There’s a bit of a knack to using it, but the results aren’t bad:

cornerblockjig

And here’s one of my new corner blocks next to an antique Lachenal one:

cornerblock

I cut the sides of my bellows frames from 9mm plywood using my Nobex Proman 110 mitre saw, and glued them together with hot hide glue:

nobexproman

After a bit of shaping, I checked that they fit in the scrap Jeffries bellows I was copying my dimensions from:

bellowsframes

Next came the bellows mould. This proved quite a large sub-project in its own right. It has six forms (one of which is split in two to make it possible to remove the forms), screwed to a hexagonal core, suspended from a stand. Making the forms was the hardest part. I started by gluing blocks of pine to strips of plywood, with the grain running across the form, being careful to avoid including any large knots:

bellowsmould1

Then I used the bandsaw with the table tilted over at 45 degrees to relieve the under-sides of the forms:

bellowsmould2

Then I used the CNC milling machine to cut the valleys into the top sides of the forms (video sped way up: it actually took about an hour to machine each form):

After I had spent days making all six forms, I laid them out next to each other and realised I had made a silly mistake: five of them were spaced wrong, and in fact all of them were pitched slightly too tight to fit comfortably inside the Jeffries bellows:

bellowsmould3

I could have tried to unglue the blocks and glue them onto new plywood strips with the correct spacing, but I decided it was easier just to start again and remake them all. By the end, I was getting really tired of the noise the milling machine made as it cut the valleys, not to mention the dust everywhere!

I made the core of the bellows mould by mitring the edges of six pine boards on the bandsaw and gluing them together. I deliberately made it slightly oversize, then hand planed it to final shape/size (a good idea as it turned out slightly wonky, plus I wasn’t certain exactly how big it needed to be until I tried assembling it inside the Jeffries bellows):

bellowsmould4

The stand is a simple affair with the vertical ends roughly dovetailed to the base. A nice feature of this style of core is that if you turn the central bar one way up, it presents the sides uppermost, and if you turn it the other way up, it presents the corners instead. This picture also demonstrates that the scrap Jeffries bellows fit on the mould:

bellowsmould5

Finally time to start making the bellows! I cut the 108 individual cards out by hand, using a template I cut from a piece of scrap aluminium to match the shape of a card taken from the Jeffries bellows:

bellowsmaking1

I hinged pairs of them together using strips of fine-woven linen cut on the bias and bookbinders’ maize paste (very similar to wheat starch paste but supplied pre-cooked and with some anti-fungal stuff mixed in):

bellowsmaking2

Then I hinged the pairs together into six strips. Note that the hinges are both on what will become the inside of the bellows, and the valley hinges have to be pasted on with the hinge partly closed or they will tend to tear themselves apart when they close. There may be a less fiddly way to do this but it seemed to work well enough.

bellowsmaking3

After the paste had initially dried, I noticed that the cards had all warped a bit, so I pressed them all tightly in a big wooden clamp for a couple of days (forgot to take a photo), which helped to flatten them out again.

I tied the strips of cards onto the mould with string, then hinged the corners together with more bias-cut linen, though at this point I switched to using hot rabbit-skin glue. It’s messier and more difficult to work with than paste, but in my tests it was the strongest of all the glues I tried (slightly stronger even than PVA wood glue, and significantly more flexible when dry).

bellowsmaking4

I made a simple press to clamp the bellows shut, and whenever I had to let the glue dry before the next stage, I took the bellows off the mould and transferred them to the press. If I hadn’t, they would have dried in the fully-open position and possibly torn apart when I tried to force them closed. It’s also necessary to periodically take the bellows out of the press and exercise them to avoid them drying fully shut.

bellowsmaking5

Next I glued on the valley leather strips. I used goatskin for all the leather on the bellows. I pared the valleys down to about 0.65mm and skived the edges for cosmetic reasons. They are simple rectangles rather than butterflies because that’s how they were on the Jeffries bellows I was copying:

bellowsmaking6

Next the gussets:

bellowsmaking7

Here’s a video of me gluing a couple of gussets on:

The top and end runs. In hindsight the end runs would have worked better if they were both narrower and thinner, and perhaps I need to work on my technique for gluing them on, because I was unable to get them to go round the corners without creasing, which caused the end sets of gussets to be stiffer than the rest. It probably didn’t help that I made the cards all the same size (the end ones probably should have been slightly taller because of the inset):

bellowsmaking8

Pressing it all together:

bellowsmaking9

To make them look a bit prettier, I made bellows papers from decoupage paper:

bellowsmaking10

I screwed a plain piece of plywood onto the bottom end, with a sheet of black “funky foam” (closed cell EVA foam sold in thin sheets for craft purposes) as a gasket, and a couple of pieces of scrap lead to pull the bellows open with a consistent amount of force:

bellowsmaking11

The top board has a reed holder next to one edge. It’s a simple design that doesn’t require any adjustment for different sizes of reed, though you do have to hold the reed in place with your thumb while sounding it. The top plate is slightly thinner than a reed frame so that it’s possible to file the reed in situ, and it has a slight undercut so as to hold the dovetailed reed frame more securely. It took some careful measurements and fiddling about to get the wind slot just right so that it works for the full range of sizes of reed I had available. It might require further adjustment if I ever want to use it with even bigger reeds from a bass instrument. The separate brass screw is used in conjunction with a specially shaped thin spring-steel shim (not pictured) to hold the reed tongue up above the frame while filing.

bellowsmaking12

Here’s the finished tuning bellows clamped to my bench. The flap of leather is a relief valve to let the air out when you raise the bellows. Not clearly visible in the picture, there are a pair of straps tacked to the sides of the frames that prevent the bellows opening too far.

bellowsmaking13

Finally, here is a quick video of me showing them in action. The reeds are the highest and lowest reeds from my antique Lachenal 48-button English, plus the A4, which is at 444Hz because it is tuned in old pitch, meantone temperament.

I want to thank Geoffrey Crabb for all his advice on the construction of the bellows moulds and the tuning rig, and also Bob Tedrow for his bellows-making essay (although my technique is quite different, I picked up several good ideas from it).

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Hand-Cut Maker’s Mark Punch

There is something magical about the ability to anneal1 high-carbon steel, work it into a useful tool, then harden and temper it so that it can hold a sharp cutting edge for a long time. It was one of the most important discoveries of the Iron Age, enabling the manufacture of tools that were far superior to those made of softer metals like copper, bronze and wrought iron.

I have made a few hardened steel tools of my own; wood carving knives and gouges, and simple punches. It is a wonderful and exciting feeling to use a tool that you made yourself.

Part of the process of hardening tool-steel involves heating it to something in the region of 760-800C2 and holding it at that temperature for a while. If the temperature is too low the steel won’t harden properly, and if it’s much too high you get a coarse grain forming inside the metal that will affect your ability to sharpen the tool. In the past I’ve heated my tools using either an open solid-fuel forge or a propane blowtorch, but in both cases it is difficult to accurately gauge and regulate the temperature. Because I need to make more tools for concertina production (mainly press dies), I’ve been looking out for a better way to heat them.

Recently I came across an old electric laboratory muffle furnace on eBay. Luckily I managed to get it very cheaply because it was described as faulty and it was near enough for me to collect it in person. It looked to be in good condition in the photos, and I figured that even if the heating element had burned out, it would be cheaper and easier to re-wind it than to build one from scratch.

heattreatoven1

The fault turned out to be very simple. It is supposed to have a fusible link inside the inner chamber that melts if you overheat it (a thermal fuse). This was probably quite easy to do because the original controller was a simple simmerstat3, and I suspect leaving it at 100% would cause it to reach melting point in about 45 minutes. The thermal fuse was missing. As a temporary measure I bypassed it and the oven fired straight up.

heattreatoven2

I learned nearly everything I know about heat-treatment of steel from Hardening, Tempering & Heat Treatment by Tubal Cain from the Model Engineer’s Workshop Practice series. It was only after I’d bought my oven that I happened to be flicking through the book and saw a picture of it: the author had the same model!

Tubal Cain had replaced the simmerstat in his heat treatment oven with an early computerised temperature controller. I wanted to do the same thing, and I could have simply bought a fairly cheap Chinese PID controller like the one I used on my glue pot (though high-temperature ones seem a bit harder to find and more expensive), but for various reasons I decided to build my own instead. I used a MAX31855 thermocouple interface from Adafruit, an Arduino Nano clone, a solid state relay, a 16×2 alphanumeric LCD (HD44780 compatible), a couple of push buttons and a rotary encoder stuffed into a plastic project box. Because I already had most of the parts other than the high-temperature K-type thermocouple (which I would have had to buy anyway) and the MAX31855, the project worked out pretty cheap.

heattreatoven3

I developed the firmware using the Arduino IDE and several off-the-shelf open source libraries. This is the first time I’ve used the Arduino system, though I’ve done quite a bit of embedded programming in the past. I must admit a decent C++ compiler and a large set of libraries made it pretty easy to quickly bolt something together, though the lack of a debugger is a bit of a pain, and some of the libraries are poorly documented and/or provided with example code that doesn’t work properly out of the box.

The most difficult part of the project turned out to be tuning the PID loop parameters. Get them wrong and the oven either never reaches the desired setpoint or it overshoots and oscillates around the setpoint. One advantage of developing my own Arduino-based controller was that it was easy to log the temperatures and power level at regular intervals to a laptop over USB, then plot a graph to figure out what was happening over time. To cut a long story short, after hours of test cycles and trying many different values, I eventually found a set of parameters that perform well enough for my purposes. It overshoots by a few degrees when it first gets up to temperature or after disturbing the system by opening the door, but I don’t believe that is enough to cause a problem. In this graph, the blip at 5200 seconds is the result of me opening the door for a few seconds:

heattreatoven4

For years I have been fascinated by how punches and dies were made prior to the invention of the rotary engraving machine. I’ve read what I’ve been able to find on the subject (not very much, to be honest) and studied some antique punches to try to work out how they were made. I decided to try making a punch from my maker’s mark to see if my ideas were practical.

I think positive punches and single-line name stamps usually used at least one counterpunch per letter to form the hollow spaces (the counters), and the outside waste was cut away with saws, files and probably a selection of gravers. There were also negative punches that were probably either entirely engraved or stamped with a set of reversed positive punches, but I’m not going to cover those today.

My maker’s mark is a fairly simple symbol (an upper case A with two arms added), though I wanted to challenge myself by making a serif version with multiple stroke widths.

I made both the counterpunch and the punch from 3/8″ silver steel, which is a commonly-available high-carbon water-quenched tool steel with a little chromium in it that is supplied as accurately ground round bar. Since the counterpunch was to be smaller than the punch I first tapered the end. There are several ways to do this, but I decided to use the compound slide on my Taig lathe. I also used the lathe to face both ends to make them square, and used a file to round over the hammer ends a little so that when you strike it you don’t hit a corner.

punchmaking1

The facing process left the end that was to become the punch square and reasonably flat but very slightly rough. Because this might effect the performance of the finished punch I decided to lap it flat.

punchmaking2

First I clamped the blank in a Vee block, using a piece of paper as a shim to make sure the punch protruded from the block by a tiny amount:

punchmaking3

Then I lapped it on a cheap diamond plate in a figure-eight pattern:

punchmaking4

The lapped face of the punch blank:

punchmaking5

Next I started cutting the counterpunch using a jeweller’s saw to make the initial grooves:

punchmaking6

I removed the waste from the outside using a fine flat hand file:
punchmaking7

Then I used a graver to widen the grooves (you can see in this one it’s pretty small compared to my index finger):

punchmaking8

The nearly-finished counterpunch:

punchmaking9

To check it was the right shape, I got it sooty in a candle flame and pressed it onto a piece of paper (this is called a smoke proof). Actually I realised at this stage that I had made a mistake, but I opted to push ahead and modify the proportions of the punch to compensate rather than starting again. I could get away with this because the design of my mark is rather fluid anyway, and doesn’t have to match the style of a particular font.

punchmaking10

punchmaking11

The final part of cutting the counterpunch was to bevel the corners and do a test punch into a piece of end-grain hardwood. I’ve found that a punch doesn’t work very well if you don’t bevel it at all, but it’s not entirely clear to me how steep the bevel angle should be (the old punches I’ve looked at aren’t all the same).

punchmaking12

Next I had to harden the counterpunch before I could use it. In order to reduce scale buildup and decarburising while soaking in the heat treat oven, I coat the business end of the tool in jeweller’s borax flux. Applying it isn’t an exact science. I warm the punch to not-quite boiling point, then smear some thick borax paste onto it and wait for it to dry. Once in the oven, it will bubble up a bit at first but then it should melt and flow out across the surface (you can see the difference after heat-treating; the areas that were protected by the flux are still bright underneath).

punchmaking13

I put the counterpunch into the oven on top of a piece of bent stainless steel that prevents it directly touching the oven floor. After waiting something like 20 minutes for it to get up to temperature, I let it soak for another 20 to ensure that it was fully austenized all the way through. From what I’ve read, not soaking for long enough will significantly reduce the hardness you can achieve.
punchmaking14

After soaking, I pulled it out with blacksmith’s tongs and immediately quenched it in a bucket of water. The shock actually causes most of the Borax flux to fall off, which is handy because it can be difficult to remove.

punchmaking15

As a quick check to make sure it hardened, I see if a file will cut it. Generally it will scratch a tiny bit because of the surface decarburisation effect but it will be hard enough underneath that the file just skates off. Some people recommend using a good sharp file for this test, but I find that it tends to blunt the file so I prefer using a rubbish file and just press quite hard (I have experienced a tool that didn’t harden properly and the difference was pretty obvious).
punchmaking16

After hardening, the steel is very hard but also very brittle and highly stressed. If you’re not careful you can shatter it just by rough handling (I’ve done that with a fancy spring clip that I had just spent half an hour forging). What we do to cure this is to temper it, which means re-heating it to a lower temperature and soaking it for a while. This reduces the hardness somewhat but also reduces the internal stress and greatly increases the toughness of the steel. If you temper it lightly you end up with quite a hard tool that might be at risk of chipping. Higher tempering yields a tougher but softer tool; if you go too far the edge may tend to roll over in use. The highest levels of tempering are used to make springs.

There are several ways to heat a tool for tempering. I could even use the heat treat oven itself, but it would take a few hours to cool down sufficiently and it’s not a good idea to leave the tool in its fully hard state for that long. I decided to use a small electric deep fat fryer with sunflower oil in it. The highest temperature the thermostat will go up to is about 200C (and the oil probably wouldn’t be happy going much higher than that), which is towards the low end for tempering silver steel.

punchmaking17

After tempering I used a rotary wire brush in the pillar drill to remove the scale and any remaining flux.

punchmaking18

Finally I used a spirit burner to re-heat the blunt end up to a spring temper so that it can better resist the shock of hitting it with a hammer. It will probably mushroom eventually but it is easy to cure that by grinding. After it reached a blue colour I quenched it again to stop the heat travelling too far up the shank.

punchmaking19

A quick test in a piece of scrap aluminium proved it had worked as planned:

punchmaking20

The first stage of cutting the real punch was to strike the counterpunch into it. I think this is possibly the most difficult part of the entire process. You have to line it up perfectly, then hit it multiple times very hard to drive it as deeply as possible into the steel. Although the silver steel is supplied annealed, it is still a pretty tough material and it takes a lot of force to counterpunch it. The counterpunch bounces out of the indentations after every strike and you have to be very careful to line it back up perfectly before the next strike – I had a bit of an accident and made an extra small dent but luckily it was in a waste area. The counterpunching causes the surface to raise up a bit around each indentation, which I opted to get rid of by lapping it flat again. Here is the result after counterpunching and lapping:

punchmaking20b

I roughly removed the majority of the waste from the outside with a jeweller’s saw and files again:

punchmaking21

Mostly done, though not yet adjusted the width of the strokes:

punchmaking22

After a bit more fine fettling, and adding the bevels:

punchmaking23

I didn’t bother photographing the hardening process as it was exactly the same as for the counterpunch. The final set of photos shows the result of testing it in several different materials. First end-grain beech:

punchmaking24

Aluminium, both a light strike and a heavy one:

punchmaking25

A light strike into side-grain pine tended to crush the soft fibres:

punchmaking26

End-grain pine worked fairly well though. The bottom one was an experiment in soot blackening the punch first:

punchmaking27

Brass. I had to hit it pretty hard to get a decent impression but it came out quite nicely:

punchmaking28

Thick leather. This looks sharper in reality than the photo appears to show:

Mild steel. The top mark was a moderately hard strike onto the wooden bench and it’s barely visible. The bottom mark was a very hard strike backed by a steel anvil. I’m not sure I’d want to risk striking the punch that hard very often as I’m concerned the tiny serifs might be at risk of breaking off, though it didn’t suffer any visible damage as a result.

punchmaking30

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