[ Andy Taylor wrote: ]

> ... The pumping pedal mats were worn all the way through, and I
> replaced them with the 'stair tread' matting.  It looks okay, but
> I couldn't help but ponder the idea of reproduction pedal mats with
> the Standard backward "S" .

Dear Andy,  In the course of developing our Tracker Bar Interface
(TBI), I have had to learn much about the molding of rubber for the
tracker bar gasket, valve facings, etc.

There are two products which are relatively easily used by any small
shop to cast rubber parts of all kinds from simple molds.  One is
Devcon Flexane, which is black; and the other is Dow Corning catalyzed
RTV silicone, which seems to be available in red and white only, the
white generally being for the softer durometer ratings.  Possibly this
product can be colored.  Both the Flexane and the silicone produce
excellent results.  For example, I made extremely soft rubber mounts
for the box-type grand Motor Player pump suspension rods with Flexane,
and these were still good many years later.

Flexane normally takes over an hour to set, while the Dow Corning
product can de-mold in as little as one minute. (However, both take
much longer to cure completely.)  Neither require air to cure.  These
setting times, as well as the durometer rating (hardness or sponginess)
can be adjusted with additives with both products.  These two companies
are most helpful in supplying information on their products' use.

Since these products are used at room temperature and are poured
and not used under pressure, the molds need not be massive nor
tight-fitting; simple aluminum, or even molded plaster of Paris or
epoxy can be used as a mold.

I have thought about making Standard, Gulbransen and other pedal mats
with Flexane.  If a perfect photographic image can be obtained (I may
have an excellent example of a Standard mat), I can have a master
photographic tool made for etching a metal plate with the likeness,
which can then be imbedded in a sturdy metal box with a lid pressing
the rubber to the desired depth, to form a mold.  The resulting etched
plates would then be relatively inexpensive for me to have duplicated,
if multiple plates were desired.

On the other hand, for a few hundred dollars more, I can have a
heavy tool-steel mold made, from which I can have rubber mats easily
and quickly cast in ordinary rubber of any kind, which would be more
suitable to larger runs, which might repay the development costs.
I have an excellent rubber molding house nearby which is willing to do
short runs and prototype work, and has fairly short lead times.

If anyone is interested in having molds made for any type of rubber
parts not extruded within a foot or so in size, I have the facilities
to do these projects or partial molds, etc., and would consider doing
them, as time permits, provided that they are paid in advance or
otherwise as requested by me.  With care, we can produce results of
at least the same quality as the originals.

Larry Broadmoore, Broadmoore Piano Company
Phone: (818) 365-6231 ; Fax:   (818) 361-0911