The Play-A-Sax is made of pot metal and most have corroded to the point
that it is very risky to attempt to separate the three major castings.
The pieces are virtually welded together, in most cases, as well as
being very brittle due to decomposition of the alloy. I would not
recommend attempting to separate the pieces unless they come apart
very easily as they are likely to break.

I have disassembled these by the following procedure which is
relatively low risk but requires the proper tools. First cut the unit
apart at the joint between the mouthpiece and the main body section
with a thin kerf metal cutting saw such as those made by Exacto. Then
carefully grind the remaining plug out of the body with a die grinder
and a suitable bit. Once the metal plug has a few areas cut almost
through to the wall of the body, the rest of the plug can be pried out
carefully without destroying the body.

To reassemble the unit, after repairing the harmonica, you need to turn
an undercut into the mouthpiece with a metal lathe. Then a sleeve is
fabricated that will fit into the body and this is epoxied into the
mouthpiece. The sleeve should have annular groves cut to accept o-rings
which will hold it in place in the body and provide a seal. This method
makes it easy to disassemble the unit in the future for subsequent
repairs. For a more appropriate looking repair, cork can be used to seal
the joint, but this is much more time consuming. Another possibility
is to cast a new mouthpiece using the old one as a model.

 [ I'd appreciate it if someone could send mail to editor@foxtail.com
 [ and let me know what the correct spelling of this item's name
 [ is.  We have entries in the Archives as PlayASax and Play-A-Sax.
 [ Spencer used the latter in his Subject line.  I changed it to
 [ make it match the thread's title, but I'm unclear what should
 [ really be in the Archive's Index.    Thanks   -- Jody