- The process starts with designing the horn's shape, size, and key combinations.
- Typically, Banda Linda Horns are made from either brass or nickel silver.
2. Forming the Bell:
- The first major part to be crafted is the bell of the horn.
- A sheet of metal is cut to the desired shape and then rolled into a conical form.
- The edges are soldered together, and the bell is polished and lacquered.
3. Creating the Valves and Slides:
- The valves and slides are precision-machined to ensure proper airflow and precise intonation.
- The valves are made from a combination of brass and stainless steel, while the slides are made from nickel-plated brass tubing.
4. Assembling the Body:
- The body of the horn is formed by bending and shaping brass tubing into the appropriate curves.
- The various sections are then soldered together and reinforced with braces to ensure structural stability.
5. Adding the Keys and Keywork:
- The keys are individually stamped or cast and then fitted onto the horn's body.
- The keywork is carefully aligned and adjusted to provide smooth and precise action.
6. Lacquering or Plating:
- The horn is finished with a layer of lacquer or plating to protect it from tarnishing and corrosion.
- Lacquered horns have a glossy finish, while plated horns have a more subdued metallic appearance.
7. Final Testing and Adjustments:
- The finished horn undergoes a series of rigorous quality control tests to ensure that it meets the high standards of Banda Linda.
- The intonation, airflow, and overall playability are meticulously checked and adjusted if necessary.
8. Packaging and Distribution:
- Once the horn has passed all the quality checks, it is carefully packaged and shipped to authorized dealers or directly to customers.
Note:
The manufacturing process of Banda Linda Horns involves a blend of traditional craftsmanship and modern techniques, ensuring the instruments' consistent high quality and musical excellence.