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Broken Key Rod

Squeezebox Of Delights

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So my main 'proper' instrument is a 1930s Frontalini, LMMH tuned with four treble couplers (16 different combinations) and one bass coupler. It's a lovely instrument, and many of the common problems associated with pre-war accordions are absent. However, a few weeks ago I noticed that one key was sticking up, and occasionally playing when I wasn't pressing it. I took the instrument apart and found that the aluminium rod connecting the wooden key to the wooden pallet had actually snapped between two rivets, allowing it to wiggle a bit. I was on a National Youth Folk Ensemble course at the time, and had three gigs and a recording session coming up, so it was possibly the worst time for something like that to happen! Anyway, the accordion still plays, but the problematic key will randomly keep playing, which makes using the instrument a fairly difficult experience. Is this a problem I can fix on my own, or is it going to be something I have to get done professionally?

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How much more can it be disassembled?
Can the broken rod be conveniently removed from the wooden key?
If so, it may be possible to weld the rod.
You could put it as an interesting challenge to an aluminium fabricator in your locality, perhaps?🤔
Or a replacement part could be handcrafted ( using the existing bits as a template)?🤔
Also, aluminium can be glued ( Google search for many suggestions, including videos)
Here's one of many glueing suggestions:
"CYANOACRYLATE GLUES – All grades of cyanoacrylate adhesive, instant glue, bond aluminum extremely well."
It may be possible to either weld or glue the broken bits to the brassy looking part for a very strong joint?🤔
Surface preparation will be essential!
Possibly, you could even rivet the broken rod pieces to the brassy thing to hold them together?
Decisions...decisions...!🤔
 
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Interesting to hear from Dingo40 that you may be able to glue the pieces together.
First however you should pry the two aluminium pieces from the wooden key part.
I suggest to then drill a long small hole (lengthwise) in both pieces so that you can insert a thin steel rod that prevents bending (and thus cracking the glued bond) between the two pieces. A hardened steel nail (without head) may do the trick as it is very hard to bend.After inserting the nail and putting the glue on the aluminium pieces you can press everything together so the aluminium rod is one piece again. You then clue it back in the wooden piece. I think this will be the best solution for this type of key that isn't being manufactured anymore.

Note: many people think that if they have a small accident like a shoulder strap catching on the end of a key and pulling it up there is an easy fix: push on the pallet end of the lever and on the end of the key so the lever is bent back until the key is back in position. However, this action puts the kind of strain on the aluminium lever that may result in the crack you have experienced.
 
However, this action puts the kind of strain on the aluminium lever that may result in the crack you have experienced.
Bending metal results in work-hardening which leads to metal fatigue which results in fracture ( cracking).
Aluminium alloys are notorious for metal fatigue. This is why re-bending keyrods to realign a keyboard is quite a risky business.
Each realignment of a particular key could be the last!🙂
 
I suggest to then drill a long small hole (lengthwise) in both pieces so that you can insert a thin steel rod that prevents bending (and thus cracking the glued bond) between the two pieces.
There is, though, the further potential problem of "galvanic corrosion ".🤔
See here:
"To join the dissimilar metals aluminium and steel, bimetallic strips are used. They facilitate the joining of dissimilar metals by welding. Aluminium and steel can not be joined by conventional welding processes. When mechanical joining techniques are used, corrosion sets in after a relatively short service life."
 
There is, though, the further potential problem of "galvanic corrosion ".🤔
See here:
"To join the dissimilar metals aluminium and steel, bimetallic strips are used. They facilitate the joining of dissimilar metals by welding. Aluminium and steel can not be joined by conventional welding processes. When mechanical joining techniques are used, corrosion sets in after a relatively short service life."
Maybe I wasn't clear. I was not suggesting to "join" (as in glue or weld) the steel nail to the aluminium of the key lever. I merely suggested to insert it so it prevents any movement in the joint between the two aluminium parts. The size of the hole should be such that the nail barely fits. (It should be hard to insert, but then if you first freeze the nail it should slide in easily and be firmly in place when it goes back to room temperature.) As the aluminium pieces are glued together no air can reach the nail. That might hopefully prevent any corrosion between the steel and aluminium. But whether it really works I don't know. So far I have not had to fix a problem like this.
 
Oh, that's a really nasty place for the thing to break! It makes the problem difficult.

Bending aluminium alloy has been mentioned. It's worth noting that many aluminium alloys can be annealed by heating. To do this, smear ordinary soap onto the surface, then heat (blowtorch or even hot-air gun) until the soap chars. The alloy will then be softened and can be bent, later, when cold, with much less risk of cracking. Beware, though: the heat treatment of aluminium alloys is complex, and without knowing the alloy's composition, the best one can do at home is the crude method above, which will probably leave the part softer, thus more easily bent, than it was originally. Some alloys will re-harden over a few days.

Regarding adhesives: a butt joint will be weak, because of the small cross-section. There's not much thickness for internal reinforcement. If I were going that route, I'd consider cutting a long slot in each piece, rather than drilling a hole, then the reinforcement can be the full width of the key rod. If there's enough room to stick doublers onto each side, across the crack, adhesive will probably work, especially with a rubber-toughened cyanoacrylate, like Loctite 480. The doublers should be as deep as possible, but can be thin material. Meticulous de-greasing is always advised for adhesive fixing. I wouldn't worry too much about dissimilar metal corrosion, if there's no electrolyte around. This means keeping moisture away, and a coat of waterproof paint, varnish, etc. will do the job. In any case, the alloy key rod is in contact with the brass piece - a prime candidate for galvanic corrosion!

Having said all that, I note that, after repair, the brass piece will have to be rivetted to the alloy key rod. This is risky for brittle cyanoacrylates, hence the rubber-toughened one advised. That might even allow rivets to be dispensed with.

I think that removal of the brass piece, followed by a favour from a friendly - and skilled! - TIG welder is the way to go. However, the welding will anneal the alloy around the weld area, so it will most likely be softer than original. Spectacle frame repairers often have laser welders these days, and will often do jobs other than spectacles for reasonable prices - and an offer of beer might help.... I don't know, however, whether they will be able to attack aluminium. If they can, it's great, because the heat-affected zone is so small, so little strength will be lost.
 
It's unlikely the metal is aluminium; it's too soft and malleable for this piece which is constantly under stress.
The key levers in almost all accordions I have seen really are aluminium (or some aluminium alloy). The forces applied to the key levers generally isn't all that great and as a result the levers can last a lifetime.
 
i personally have only ever seen one pivoting action type..

i have therefore of course never seen one from pre-WW2

but for those of you who have seen more actions, doesn't
the lack of a pivot rod hole strike any of you as odd ?
 
but for those of you who have seen more actions, doesn't
the lack of a pivot rod hole strike any of you as odd ?
It's actually one of my favourite things about this accordion. The keys have brass hooks which hook onto a static steel rod under the keyboard. A sprung metal bar holds the keys in place so they don't fall out. This means that removing keys is as simple as pressing a catch under the grille that clicks satisfyingly into place, and popping out the key that you wish to work on. Quite unusual for a pre-war box I think, but I have two of these posh Frontalinis that both have this feature.
 
Thanks for all the advice so far, I'll get the poor thing out when I can, and see if I can remove the key rod. I don't know if the rivets are press fit, or if they're properly riveted. We'll see!
 
neat !

then Scandalli perhaps didn't actually invent this.. just "refined" it ?
eliminating the steel rod for an aluminum form
 
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