Thank you to all that replied. Your thoughts have been printed out and compared to the piano and this is what I have come up with so far. Taking the posts somewhat in order I will respond to questions and suggestions.
Tom and Barbara: It is quite possible that someone did exchange the action brackets in the past and put on the wrong size. The ones on there now seem to be solid. I have worked with expanding brackets and they showed cracks and fell apart in places when handled. On reexamining these, there are two cracks where the brackets are tapped to receive action bracket bolts but no other sign of deterioration. They are numbered 108 if that means anything to anyone.
Tom and Roger: My observation of the relationship of the capstan with the whippen cushion was wrong. I got there by observing the capstan from the bass end of the piano with the action on the keys. What I did not realize was there was a chunk out of the cushion on the first bass whippen. When the stack was removed from the keys and turned over, it became obvious that I had made a mistake and that capstans were in the correct position.
Jurgen and Nicholas: You are quite correct that the let off should not have been included in the figures. It's because of the possibility of incorrect thought processes like this that I ran this past the list before making what would have been costly and even more disastrous changes to the action. Thank you for catching this mistake.
Wim and Keith: The starting blow distance may be somewhat of a problem because I had to change key height to get the action to play. At this point there have been test keys that have been setup to check the parameters of key height, dip and clearance to case parts. There is very little that can be done with the key height because the back of the balance rail has no relief and the key hits if the backrail cloth is to low, and the balance rail pins for the white keys are so low that they barely come out of the top of the mortise with the thinnest punching underneath. The blow distance at this moment is hovers around 50mm. The hammers will need to be reshaped so that will give some more blow distance. Even then it is going to be close because the shanks will be just barely clearing the hammer rail. The knuckles are not too flat.
Jurgen: I don't work in metric, but half of the measurements were going to have to be metric on this piano so I looked up a program on the internet that did the calculations, plugged in the inches (converted from fractions to decimals) and copied exactly what it gave me. Sorry for the confusion that caused.
At this point in time, it looks like the action may be able to be made to work with reducing the hammer bore by reshaping, lowering the hammer line with slightly thinner backrail cloth, and possibly using a thinner cloth on the hammer rail if needed. Eventually a new set of hammers will be needed, but not until the summer at the earliest.
Thank you again for everyone that jumped in to help. It's always good to have an extra set of eyes. I have printed your replies and will refer to them as I work this out.
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Rex Roseman
Akron OH
330-289-2948
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