RUDALL CARTE Ebonite Restoration - a work in progress
20 April 2026: After several months we are finally (almost) ready to let this flute sing again!
For our latest project we chose to restore a complete, original, but worn Rudall Carte, a flute that deserved to be brought back to as-new playing condition. This flute was made by one of the great Rudall Carte craftsmen, Henri Nivarlet, so we could be certain that when it left his hands 120 years ago it was wonderful.
We were particularly interested in restoring this flute because its body is made from ebonite. At the time it was made ebonite was considered an excellent flutemaking material not only for its warm yet direct sound, but also because it can resist changes in heat and humidity without cracking. In our modern world of heatwaves, central heating, and air conditioning we believe ebonite's qualities make it a valuable alternative to wood.
Firstly we removed all keys from the tubing and repaired as necessary. We converted the five fingered keycups to open-hole and turned Delrin grommets on our lathe. Then we fitted all the keys to either new silver tubing or replacement original Rudall Carte silver tubing. Much of this was silver soldered for extra strength (originally it was lead soldered, and these joints can deteriorate with age). In remaking the mechanism we were able to eliminate all play so the keys feel immediate and reliable under the fingers, and the player can have complete confidence in the flute.
As on most Cartes, the RH touch operated the thumb key. We converted this to work the Bb, which would have been an original option so not historically inaccurate.
Once all the keywork was ready we reassembled it and began fitting it out. The new pads are now in place and we about to move on to the last few jobs of fitting all new springs, corks, and regulating shims. So, after several months, we are keenly working towards that marvellous moment when we can play the flute for the first time in its newly-restored condition.
Once we have fitted out, regulated, and oiled the mechanism, we will finally be able to hear the flute's voice. Then will come the gradual playing-in of new pads and connections as the flute comes to life once again.
