Is a better question to ask if anyone knows of any local lutheriers to southern california who can do this basic work? I know LA bassworks, Lemur, and FMI can do it, but anyone else you can think of?
The problem with using your new endpin plug, wrapped with sandpaper, is that it's only going to remove material correctly where the plug is. However, the plug is going to be back from its eventual position, first because the hole's too small, and secondly because it's got sandpaper wrapped around it which increases its diameter. So you'll end up with a hole that's probably correctly tapered at its widest portion, but then where the end of the plug is, the hole's ID will suddenly become smaller; and your new endpin plug is going to hang up there. Now you've got a tapered plug that's hitting a too-small part of the hole, generating tremendous hoop stress there, and yet it's still loose at its wider portion. The harder you try to jam it in there the more likely you are to crack the tail block, or bugger up the plug.This is an interesting topic for me.
The reason I know about the proper reamer for installing a DB endpin plugs is that I've had to research it for myself...
My Alcoa's endpin plug, which today is probably the only original piece of wood remaining on this DB, is glued into the aluminum "end block" socket with a horribly aggressive green aeronautic adhesive. This was done long before I ever owned the DB. The endpin plug itself is cracked and looking pretty bad, but still functionally intact having somehow survived to this date. But I know and am prepared to have to replace it one day...
In order to do that, because it is more or less permanently glued in, I'll have to drill out most of the old endpin plug, and then ream out what is left with the proper angle and taper, just enough that a new modern endpin plug will fit in its place.
Because the aeronautic glue is so nasty, and also because of the chance of hitting aluminum in the process, I can't ask a luthier to do this work and possibly ruin their reamer. So I'll try the adhesive sandpaper on the new endpin plug trick first, and failing that, order a proper reamer for myself. Either way, I'm not looking forward to this project. The old endpin plug, along with a short endpin to work with my height, has lasted with me for going on 7 years and I'm just hoping it might outlast me.
Soooo, guess what arrived today!!! And guess what I did after it arrived!!!
View attachment 5409435
From right to left:
1) There's a male/female double face velcro belt to hold the strings in place on my Alcoa after they were loosened enough to free the tailpiece off of the old endpin plug...
2) There's a brand new 1" drill bit to drill out the old endpin plug enough that the reamer can be used; the reamer is not an awl, so the hole would have to exist in order to use the reamer.
3) There's the reamer, a wonderful piece of hand tool.
4) There's the case the reamer came in so that its razor sharp edges wouldn't cause damage or injuries during shipping.
5) There's the old Alcoa endpin plug with the installed short endpin I made for it years ago, still in place.
What isn't shown is the hair dryer that I used to heat the old endpin plug and surrounding Alcoa aluminum with. Also not shown is the heroic old 16" pipe wrench (and its duct-tape covered jaws) with which I was able to remove the old endpin plug -- that pipe wrench has rescued me at least a dozen times in the past, and once again, it is the star of the show.
I don't know if the heat helped, but with the pipe wrench I was able to wiggle loose the old endpin plug despite the nasty glue, and eventually to pull it out. The old endpin plug suffered multiple chips and a complete split through the old cracks in the process, but it came out mostly as one unit.
Once the old endpin plug was out, I only used the new reamer to gently clean out the old glue that was still inside the Alcoa cone, and then I installed the new endpin plug and assembly. It is SOLIDLY in place after a few firm but gentle taps with a rubber mallet and NO GLUE, and it works great. Here it is (sorry so blurred, I was in a hurry to play the DB):
View attachment 5409442
Using heat and the pipe wrench was my last ditch effort to avoid real nastiness with the pernicious aircraft adhesive, and very happily, it worked.
So, I barely needed to use the reamer, but having it showed me that I would need the 1" drill bit in order to ream out the old endpin plug. And I also didn't need to use the brand new 1" drill bit to drill out the old endpin plug in preparation for reaming. But having them both available to use if necessary gave me the confidence to move forward with the project.
The endpin plug project was completed within about 30 minutes. Re-setting up the DB afterward took about an hour.
It might be helpful to ACTUALLY read the posts.So as soon as a luthier says its ok for someone to attempt a job the gatekeepers back off. I'm with hoochie coochie man, take pride in doing things myself. This place will shame you for it. A pornstar could probably f my wife better than me however, I prefer to give it my best shot and do it myself.