By: JL Bowers The Bandroom

Items needed:

1) 3/32" Thick Cork Strips
2) Screwdriver or other scraping tool
3) New (SHARP) single edged razor blade
4) One container of contact cement
5) Clarinet Bench Jig or #16 finish nail and hammer
6) Black Electrical Tape
7) One 1/2" strip each of 120 grit and 300+ grit sandpaper
8) Corkgrease
9) Paper Towel

Step One: Remove the old cork from the tenon on the clarinet with a light duty screwdriver or other appropriate scraping tool. Make sure all the old glue is removed as well. If some of the areas are stubborn, use a small soft-bristled wire brush to gently remove the excess material. Take care not to scrape the body of the clarinet with the scraper of choice and also not to scratch the body with the brass brush.

Step Two: Measure the width of the tenon cork 'bed'. Normally the width is either 3/8" or 1/2". Insert your strips into the 'bed' to assure an appropriate fit. If the strip is a little wide, simply trim the edge using a metal straight edge and your razor.

Step Three: Lie the cork strips on a flat smooth surface. On one end of each strip, use the razor to cut a 'bevel' on the end. It should be about a 45 degree angle. Discard the 2 small remaining pieces of cork. Flip the cork strips over so that the underside of the strip is facing up.

Step Four: Now that your strips are prepared for installation, brush a thin layer of contact cement over the entire surface of the underside of the strip. Take care not to allow the cement to run down the edges which will glue the strip to the surface. Also, brush a thin layer of glue inside the tenon 'bed' on your clarinet body section(s). Allow the cement to COMPLETELY DRY on both the strips and the tenon 'beds'.

Step Five: Once the cement is dry, flip the cork strips over. The bevel you cut in step three is the point at which the strip will wrap around itself. Taking into consideration the alignment of the entire strip, attach the strip to the tenon 'bed' and press the bevel FIRMLY into place. Do not wrap the rest of the strip around the tenon just yet.

Step Six: Brush a small amount of cement onto the top side of the bevel and allow to dry. This will create a strong bond where the strip wraps, keeping it from seperating. Once the cement is dry on the bevel, wrap the strip SLOWLY around the tenon 'bed' pressing out any air pockets while keeping it straight as you progress. When you reach the bevel press the strip together FIRMLY for a few seconds to assure an excellent bond. Make sure you do not attach the strip to itself past the bevel.

Step Seven: Now that you have wrapped the strip correctly, you need to remove the excess piece of cork strip past the bevel. Simply slice the excess off from the underside of the piece with your razor. Try to cut it at an angle opposite to the way you cut the bevel in step three. It doesn't have to be perfect at all, just close.

Step Eight: In order to sand the tenon, you need to be able to secure the clarinet body section while you are sanding. The best way is with a bench jig, which we sell for $12.95. However, you can also achieve success by driving a #16 finish nail into the side of your wooden workbench or other work station, leaving about a two inch protrusion. Wrap some black electrical tape or other material around the nail protrusion in order to prevent scratching the clarinet. Place the section of the clarinet against the bench with the nail inside the bore. The nail will serve as a 'holder' for the clarinet section while you sand. Press up against the opposite end of the clarinet section with your side or stomach. This will hold the body section firmly in place while you sand. Using your coarser 120 grit sandpaper strip, sand down the point where the strip wrapped around itself until it is as smooth and even as the rest of the strip. Remember, you are 'rounding out' the strip, so sand in a circular-type motion. Don't rush it, use a light even motion and remove the excess cork a little at a time. Cork is delicate and can be shredded if you aren't careful.

Step Nine: While continuing to hold the section firmly, use the finer 300+ grit sandpaper strip and 'bevel sand' the edge of the tenon strip all the way around on each side of the tenon. You can also buy one of our SANDING DETAILERS for $9.95. The bevel will create a cork 'build up' in the center of the tenon and eliminate the possibility of the strip getting burred when assembling or disassembling your clarinet.

Step Ten: Now that you have the tenon strip sanded and looking nice, it is time to 'fit' the clarinet together. Using your bench jig and fine sandpaper strip, 'lightly' sand the center (not the outer two bevels you made) of the tenon strip all the way around. Test the fit of the male tenon against the female receiving end until it appears that it will assemble nicely with light pressure. Place a small amount of corkgrease around the tenon strip and wipe off the excess with a paper towel. Try and assemble it again. The tenon is perfect when you need to 'twist' the sections slightly in order to get the sections together. You certainly do not want to have to 'force' the sections together.

Now, test play the clarinet to make sure it isn't leaking and enjoy your new tenon for years to come!