In reply to Mike Haydon ...

I took a course on flute restoration from the master flute mechanic at
Powell several years ago, but I never subsequently took up the craft
myself.  Here's what I remember.

A flute should be repadded with the same material that was used
originally.  (Does this advice sound familiar?)  It's a material very
much like pouch leather.  Sorry, I do not have sources available.
You'll have to hunt around.  Try asking your local orchestra's flautist,
or a school band director.  (Also see below.)

The most important thing is to ensure that there are no leaks.  You'll
need feeler gauges.  To make some, get some cigarette paper and an
extremely small pair of good scissors.  Cut a few strips about 3 mm wide
and 2 cm long.  (Actually, the handiest shape for gauges is with a tab
or handle that's big enough to hold with your thumb and forefinger,
narrowing suddenly to the 3 mm strip.)  When you've placed the new pad
(no shellac yet), use a feeler gauge, moving around all positions of the
hole.  At moderate pressure, the same as a flautist would use, there
should be no difference as you try all 12 of the "clock" positions.  If
the paper slips through too easily, you will need to shim that area
behind the pad.  It helps to keep notes and a "clock" drawing for each
key as you work, so that you do not become confused.  Cut appropriately
shaped pieces of cigarette paper for shims.  Don't put in the shellac
until you are satisfied with the fit.  A good pair of tweezers is
helpful.

The easiest way to warm the shellac is with an alcohol lamp.  You'll
find a large sewing needle handy for transferring tiny amounts of
shellac.  Keep the shellac in a small plastic pill bottle--the kind
without the supposedly child-proof cap.

While you're at it, you can take out the long screws that hold the keys,
and clean and lubricate.  Sorry, I do not remember the recommended
lubricant.  To start on finding the right lubricant and other supplies,
you might call the Haynes Flute Company at 617-482-7456 or the Vern Q.
Powell Flute Company at 617-647-4111, but remember they are tiny
companies making very expensive concert flutes, and do not have the
resources to provide any supplies, nor to engage in long conversations
about non-Haynes or non-Powell flutes.  Another source for flute
information would be any of the band instrument companies in Elkhart,
Indiana.  (Or have they all moved to Korea?)  I don't have those
listings handy.

There is often a problem getting low C and C# (on the foot joint) to
seal correctly, because the mechanics of their placement makes it
difficult for the flautist to place as much pressure on them as on the
other keys.  You'll just have to be more careful there to get everything
perfect.

--Peter Neilson
  Sanford NC