Recently I posted my thoughts on giving an estimate of hours needed for
a Duo-Art restoration.  As a postscript to my estimate, I said
"unforeseen problems always arise."  That was a very prophetic
statement, as it just occurred in my shop today.

I am rebuilding an Ampico B drawer for my personal use.  The entire
drawer is original and most tubing and cloth is still supple.  But time
is running out on this original material, and a rebuilding is
indicated.  The unforeseen element was in the re-roll/repeat pneumatic
and associated pallet valves (see page 51 of the original Ampico 1929
service manual)

The recovering of the double pneumatic was complete.  Three pallet
valves on the back of the unit were stripped of old leather and new
leather was installed.  Fresh shellac was sprayed on the entire unit,
with the working area of the pallet masked off.  And when the entire
thing was reassembled, the pallets all leaked!  That is not supposed to
happen with an experienced rebuilder.

So I took everything apart to examine what was wrong.  It was all as
clean as a whistle, it glistened, and looked brand new.  There were no
cracks in the wood that serves as a mounting for the double pneumatic
and also as the platform for the three pallet valves.

I held it up to the light at the window for a better look.  It was then
that I saw the vertical board for the pneumatic mounting and pallet
platform was really warped.  The bow in the piece, from bottom to top,
kept the pallets from seating.  I had done nothing in my shop to create
this warp.  That means that the factory must have used unseasoned wood
in production.  I have had pallet valve problems in the past with this
same component, but I never suspected that the wood was so badly
warped.

The bottom line of this discussion is that, if I were doing this for a
customer, I would have to charge for the time required to make this
part from new stock.  Most of us who rebuild for others assume that
these issues won't surface if the component has never been subject to
abuse or damage.  But here is proof that unforeseen circumstances do
occur when logic says they shouldn't.

I have to make a new board, with three air channels in the vertical,
three air channels in the horizontal, six holes for guide pins for the
pallets, three pilot holes for the spring screws, and then I have to
drill holes for mounting the double pneumatic and finally drill holes
for mounting this board on the horizontal base.

How do you put this in an estimate?  "Unforeseen problems may arise."

Bob Taylor
Missouri