Yes, the key bonding fixture sets the correct depth for the key steel in the white keys. The “stop bump” sets the correct depth in the black keys.
Yes, a smooth thin layer is required for an even, quiet hammer action. Note: WD-40 is a great solvent for the heavy grease and is helpful in clean-up and removing grease from the rail if too much is used on your first try
Assuming all the keys have a good straight and flat bond, most of the characteristics you describe will be addressed when fully assembled with key guides and key riser in place. Uneven keys can be adjusted by hand twisting to the desired orientation.
Part of the slit must pass though the sensor beam or the note will not trigger. Excess plastic in the slit can be removed with a razor cutting tool, if necessary, and just clear enough for any light transmission (the entire blocked section does not have to be removed).
The numbers correspond to specific hammers that are out of position. In this case, the numbers 0 22 0 indicate the hammers of D# (of octave 1) and G (of octave 2) are
out or position. How do I know? Refer to photo “bmap 1” and you will see the bmap values for each key in the two octave key base set.
Notice that the key values are divided into three sets of eight numbers (80, 40, 20, 10, 8, 4, 2, 1). The first 8 keys
starting from left have values in the first position. 80 0 0 represents key #1 (F) within the first set of 8 keys, with 0 keys represented in the second set of 8 and 0 keys represented in the third set of 8 keys. The same series applies to the second and third set of keys asthey occupy the center and right positions in the number set. If two or more key hammers are out of position, each key number will show in its proper placement order. For example, the reading “10 80 40”, indicates issues with G# in the first set of 8,
C# in the second and A# in the third. If two or more key hammers within a given set of 8 are out of position, then the number is an additive term. For example “0 0 28” shows
the first and second sets of 8 are good (0 0). Given the additive nature of the system, 28 represents issues with B (20) and/+ C# (8) = 28 in the third set of 8 keys.
When using the key fixture to bond the plastic key to the key steel, there is a tiny gap between the end of the key and the raised "stop bump" on the key steel. Is this by design?
The heavy grease used on the key base hammer rail is extremely thick and sticky and I am hesitant to use it as instructed. Is it really necessary?
I have completely assembled one key base and have noticed a misalignment of some keys and one that is slightly tilted. How can I make the appropriate adjustments?
The thin slot on the hammer fin is not complete on a few pieces in the kit. Will this effect the board function in any way?
I assembled two complete key bases (2 octaves each) and tested individually. The first tested fine indicated by the following output on the control screen: “Sensor 1 Keys Up v 1.1”.
The second had a different output indicated on the control screen as “Sensor 1 bmap 0 22 0”. What do the bmap numbers mean?