Some steps of making a soundboard are invisible after the board is built. Fitting the ribs to the rim of the piano is one of those details that is unseen, but I believe is important in achieving a good sound when the board is completed. I start by rough cutting the length of the ribs. The original rib dimensions are usually duplicated. Then the width of the individual ribs are cut and planed smooth. Now the exact length of the ribs is determined by hand fitting each to the notches in the rim of the piano. Next a radius is cut on the face side of the rib. Finally, the ribs are cut to their proper thickness and planed smooth. At this point, the reliefs are cut out of the ends. The cut outs are saved to use as cauls when pressing the board. A final hand fitting of the ribs into the rim is done, checking all aspects of the desired dimensions. This attention to detail is one step in recreating a great sounding piano soundboard.
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