How to Replace a Broken Pin on a Sonor Palisano Xylophone

Tools and Materials Needed

• Drill bits (various sizes): To create pilot holes and carefully remove the broken pin.
• Nut driver or drill: For operating drill bits with precision.
• Wood glue: Used to secure the new pin in place.
• Toothpicks or small wooden sticks: Useful for adjusting the fit if the original hole has widened. A wooden Q-tip can work as an alternative.

Step-by-Step Replacement Guide

1. Preparation

To ensure a smooth and safe repair process:

• Clear and organize your workspace: Have all tools and materials at hand.
• Check for additional wear: Examine other pins to see if they also need replacing, saving time for future maintenance.

2. Removing the Broken Pin

• Drill a Pilot Hole: Start by drilling a small pilot hole directly in the center of the broken pin. This guides the larger drill bit and reduces the risk of damaging the surrounding wood.
• Remove the Pin with a Larger Bit: Using a larger drill bit, preferably around 1/8 inch, carefully drill out the remaining part of the pin along with any residual glue. Go slowly to avoid widening the hole or splintering the wood.

3. Preparing the Hole for the New Pin

If the hole has expanded from prior repairs or wear, you may need to tighten it:

• Adjust the Fit: Insert a toothpick or a small piece of wood into the hole to create a snug fit for the new pin. Trim any excess wood so it doesn’t obstruct the new pin’s placement.

4. Installing the New Pin

• Apply Wood Glue: Apply a small amount of wood glue to the new pin for added security. This step not only holds the pin in place but also aligns with Sonor’s factory standards, ensuring a durable repair.
• Insert the New Pin: Carefully place the pin into the hole, checking that it’s aligned and positioned securely. The glue should help keep it in place once it dries.

5. Finishing Touches

• Allow Glue to Dry: Let the glue set for several hours, ensuring the pin is fully secure before using the xylophone again.
• Clean the Xylophone: During drying time, clean the xylophone bars with a gentle soap and water solution. Wipe down both the interior and exterior of the instrument to remove dust and particulates that can interfere with sound quality.

Replacing a broken pin on your Sonor Palisano xylophone can restore its function and extend its life, allowing you to enjoy clear sound quality. Regular maintenance, including cleaning and checking pins, will go a long way in preserving the instrument’s performance.

For further assistance or a visual walkthrough, watch our tutorial with Randy Hargis, education consultant at West Music.