1. Machining In this step, a computer-controlled lathe is used to machine a brass rod to form the valve casing. 2. Ball sizing Here a ball is passed through the valve ports to set their inner dimensions. 3. Brazing The port tubes are attached by brazing to the casing. The flux used in brazing is carefully cleaned off, and the internal diameter taper, the screws, and other parts are precisely machined. 1. Machining In this step, a computer-controlled lathe is used to machine a brass rod to form the rotor. 2. Lapping In this step the rotor and the valve casing are meticulously lapped and checked 1. Soldering In this step, the parts are assembled and secured by soldering. Care is taken not to apply excessive force. 2. Polishing Here the surface of the horn is polished using a buffer cloth and a polishing agent. 3. Lacquering The surface is cleaned as a pretreatment, after which an electrostatic coating of lacquer is applied in a special dust-free room. 4. Adjustments In this step, the rotary valves and slides are lapped and fitted by hand. 5. Inspection (exterior, functions, playing test) Before a French horn leaves the factory it goes through a thorough test. This includes testing its pitch with a strobe tuner and checking for air leaks using an air leak tester. Yamaha uses computer-controlled, leading-edge technology in order to provide mouthpieces that play well and have precise, consistent sizes. We have succeeded in improving the cutting precision tolerance for the cup and rim to 0.01 mm or better. This not only ensures an extremely precise shape, but provides a machined surface that is glossy and incredibly uniform. At the same time, we have worked hard to eliminate inconsistencies. We carefully check the throat diameter, shank diameter, and other critical points on each mouthpiece using special gauges. Our advanced quality control measures include micron-level precision tolerances. What are French horns made of? French horns are primarily made of brass, which is an alloy consisting of approximately 70 percent copper and 30 percent zinc. Copper alloys are widely used in wind instruments because they are less corrosive and easier to machine than iron and other metals, and especially for their superior toual qualities.   French horn bell materials and colors Material Color Alloys Tone features Yellow brass (brass) Yellow Cu:Zn 70:30 Strong , rich Gold brass Red Cu:Zn 85:15 Warm, dark Nickel silver (German silver) Silver Cu:Ni:Zn 65:20:15 Large , clear * Cu: Copper Zn: Zinc Ni: Nickel Different ratios of metal components in bells have different tone types. Why does the bell face backwards on a French horn? The backward-facing orientation of the bell on a French horn gives the instrument a soft tone. How long is a French horn when it is stretched out? F horn (YHR-314): 3.65 meters B flat (YHR-322): 2.71 meters (short for a French horn) French horns are about two to three times longer than a trumpet. Why do French horn players put their right hand inside the bell when they play? In the old days, French horns did not have a rotary valve, so players would put their right hand in the bell to adjust the pitch. Nowadays, French horns have rotary valves, but the old tradition is still followed. The pitch of French horns is designed based on the assumption that players will put their right hand in the bell while playing. If you try to play a French horn without putting your right hand in the bell, the sound will end up being too sharp. What is a detachable bell? A detachable bell is one that you can un-screw from the horn so that it can fit into a narrower case. Where did French horns get their name? There are various theories about this. One of these theories has to do with a small, signaling horn known in England as a hunting horn (post horn). This horn was used to give signals while hunting. At some point, someone brought over a larger horn from France, which was used just to play music. This larger horn came to be known as the French horn in order to distinguish it from hunting horns. Go to Horn Factory Tour Top Page