Proto-Type Project

I am finally able to put ideas I've had in my head a reality.  I am taking a Yamaha YHR-302M Marching Horn which is in Bb; basically the Bb side of a modern double horn, and putting an F extension on it.  This is basically making it a compensating front facing horn, with three piston valves and one thumb rotor valve.  My goal and idea for this project is to have a quality instrument that maybe one day will be taken seriously in the symphonic wind world.  If not, at least an option for young horn players who can't physically play a double, but are developmentally ready to.  So far I have taken a third valve from an old King Horn:

then removed the slide tubes:

sawed off the knuckles on the valve casing and sanded down the edges:

Put together the complete valve, including a plastic stop plate and valve cap from the parts bin:

 

Here is where I am as of 11/11/11:

As you can see in the picture below the valve is taken apart.  I also have two 45 degree  brass knuckles and a sheet of brass.  I will be akneeling the brass and shaping it to the casing, and forming the knuckles to the casing.  I will then be silver soldering the knuckles to the brass "patch" drilling the holes into the patch, then soft soldering  the patch onto the valve casing.

 
Made the patches:

shaped and fit the knuckles to the patches and then silver soldered them on:

dremeled the ports:

and soft soldered them onto the valve casing:  (they're a little messy but I got them to seal)