Bell protection idea - input please

[jma78]

I've for some time been thinking about how to build something that will protect the bell when traveling (=flying).

I've been thinking about putting a big plastic bag inside the bell and fill it with foam polyurethane. This way one would get a perfect and lightweight cone to protect the bell from the inside.

Would the material be strong enough to take some hits.

And to the problem. Polyurethane expands when it dries. Would this expansion be so strong that it actually would destroy the bell?

Is there some other material that perhaps would work better for this purpose?

Input from knowledgable tech people would be appreciated.

[Ferguson]

What you propose may work. I don't know the properties of this foam, whether its expansion would damage the bell. Some instrument makers do pack their instruments this way. I did have an Alex tenor tuba slightly damaged by expansion of the foam sprayed over the top of the instrument. A key lever was bent, but easily fixed.

My concern is that your foam cone would not go down far enough to do any good. I think this is a better idea, which I learned from Gronitz. Go to a carpet store and get a piece of the cardboard tubing from the center of a carpet roll. Then put a 1'x2' piece of bubble wrap down the bell, insert the tube as far down as it can go, then cut it off about 1" longer than needed to wedge the tuba into the hard case. Put more bubble wrap down the bell around the tube to keep it centered. The tube is doing the job of pushing the bell flare away from the end of the case, and the tube is holding the horn by the bottom bow, which is much stronger than the bell flare. For larger tubas, use a 2'x2' piece of bubble wrap in the bottom, smaller tubas use a bit less.

If you can't find any big cardboard tube, you can make something similar from a sturdy box. Just score parallel lines about 3" apart on a flat piece of cardboard, then roll it up into a sort of square tube to mimic the above, tape it to hold its shape, and it works about as well.

Since I've been packing tubas this way, I've had no problems.

Best,

Ferguson

[Jess Haney]

just a thought but In know of a couple that flies with their tubas to England from the US and they stuff part of their clothing wardrobe into their bells when they travel. Not particulairly light weight but it seems to do the trick.

[Rick F]

Go to a carpet store and get a piece of the cardboard tubing from the center of a carpet roll. Then put a 1'x2' piece of bubble wrap down the bell, insert the tube as far down as it can go, then cut it off about 1" longer than needed to wedge the tuba into the hard case. Put more bubble wrap down the bell around the tube to keep it centered. The tube is doing the job of pushing the bell flare away from the end of the case, and the tube is holding the horn by the bottom bow, which is much stronger than the bell flare. For larger tubas, use a 2'x2' piece of bubble wrap in the bottom, smaller tubas use a bit less

This is what the Horn Guys recommend now. Oh, wait... this is the horn guys. Duh?

[Ferguson]

Bloke, compliments to you for your many helpful contributions to this board. I am informed and entertained because of them. I do disagree with you on this one. YMMV. I've unpacked tubas shipped with a beach ball in the bell, and the beach ball had deflated during the trip. I also once got the deluxe treatment from DBSchenker, who wrecked 2 Miraphone 282 tuba bells that had the beach ball packing. Since then I've been leery of inflatable sport products, and have used the cardboard strips or cardboard tube in the bell with no issues. I'm thinking weight and inertia of a tuba can overpower a beach ball.

Best,

Ferguson
/horn guy
//vacation soon
///slashies in 3's

[Art Hovey]

I tried the foam from a spray can once. The stuff only hardens near the surface, and remains a gooey mess deeper inside. Let us know if you find a kind that works better.

[Dean E]

Bloke, compliments to you for your many helpful contributions to this board. I am informed and entertained because of them. I do disagree with you on this one. YMMV. I've unpacked tubas shipped with a beach ball in the bell, and the beach ball had deflated during the trip. I also once got the deluxe treatment from DBSchenker, who wrecked 2 Miraphone 282 tuba bells that had the beach ball packing. Since then I've been leery of inflatable sport products, and have used the cardboard strips or cardboard tube in the bell with no issues. I'm thinking weight and inertia of a tuba can overpower a beach ball.

Best,

Ferguson
/horn guy
//vacation soon
///slashies in 3's

If moved by air transport, then the balls will expand and may leak air. When back down to sea level the balls would be underinflated. Same thing for ground shipment across the US continental divide.

Regarding foam, products are designed with varying degrees of expansion.

[aqualung]

I have used a cheap soccer-size ball made of dense foam rubber, cut in half, to successfully ship baritones.

Don't know if something bigger, suitable for tubas, exists.

[iiipopes]

In addition to the above, measure the circumference of the bell rim, purchase that length of plastic tubing in the proper size, which I think is either 3/16 or 1/4 I.D., split the tubing lengthwise with an exacto or utility knife, and put it around the bell rim to have added protection against damage. The last time I did this, I think at the local hardware store the tubing cost me all of @$1.50. I just leave it on for general knocks and dings otherwise.

[Ferguson]

Now I see what you're talking about. Those are beach balls? They still make those? I am a bit dubious still, but I like the idea.

-Ferguson
/no toy store in my town

[TheHatTuba]

Now I see what you're talking about. Those are beach balls? They still make those? I am a bit dubious still, but I like the idea.

-Ferguson
/no toy store in my town

Wal-Mart supercenters and the like carry them as well.

[Ferguson]

You will not see me inside a Walmart.

Ferguson

[arminhachmer]

Recent experience makes me think a piece of plywood next to the bell and a bit bigger would stop pressure on the bell. A layer of foam between the plywood and the end of the container would keep it snug . A layer of foam between the plywood and the bell as well.

[Sam Gnagey]

The ball in the bell is certainly right. I never ship a horn with the bell end down. Even with the ball there is still a chance of damage with the bell end of the horn at the bottom of the box. Best is with the back of the horn down. A lot depends on how well the package handlers pay attention to the "This end up" label.

[Rotaryclub]

This ball in the bell thing is silly. Think about it please. Picture your horn with a ball or any thing else whatsoever in your bell, then stomp on it. Nothing at all will protect your bell except a solid metal insert filling the entire bell and weighing a ton. If you can squeeze or squish the material at all it's not going to protect anything.

The goal IS to prevent movement of any part of the horn toward anything else that will bend it (the wall of the case for starters). Once I had a shop weld an aluminum wedge shaped case, and the inside was simply made from that expandable foam stuff out of a can (a lot of cans). Positioning the tuba in the case and using mylar so it wouldn't stick to the sides or tuba, I made two halves and the tuba snapped into each piece like a glove. Then I used spray adhesive and lined both halves with felt for softness. There was NO movement and I would place this idea above any other type of flight case. It supports every inch of the horn at all places. The whole thing was under $400 at the time. You can attach any wheels or handles you like on it.