Behind the Scenes

How to Reissue a Record page 3 After hours of A/B-ing the tape and applying different amounts of equalization (ranging from none to a fair amount), preparations are made to transfer the results to lacquer. A master lacquer is an aluminum disk, 14 inches in diameter and 1/8-inch thick. It is coated with a thin film of lacquer on both sides (only one of which, however, is recommended for use). This disk is put onto a lathe platter that spins at speeds of 33 1/3, 45, or 78 rpm. The cutter head is suspended on a motorized carriage, which moves linearly across the lacquer disk. Its speed is computer-controlled so that the resulting grooves do not run into each other. Cutter heads, like loudspeakers, contain magnetic coils, which are attached to a cutting stylus that resembles a V-shaped chisel. As the tape is played on the mastering deck (see below), its signal is amplified and sent to the cutter head, which continuously changes the position of the heated cutter stylus. This device cuts through the thin layer of lacquer material like a hot knife through butter. The resulting V-shaped groove is a physical analog of the master tape's stereo signal. Bernie Grundman about to start cutting a lacquer. The carved-out lacquer material is continuously vacuumed away from the cutter stylus and collects in a nearby container. After a complete LP side is cut, the lacquer is inspected with a microscope attached to the lathe (see below). The engineers examine it for a clean cut, making sure that no grooves have collided. It is interesting to note that the musical selections on the master tape are organized into a continuous LP side (including the silent spaces between the album tracks), so that the transfer can be made without stopping and starting the spinning platter. Bernie Grundman at the lathe, checking the grooves after cutting a side. The lacquer is then placed in a container and sent to the plating plant as soon as possible. The packaging is made of Styrofoam to minimize changes in temperature. Since the freshly cut lacquer material is somewhat malleable, its grooves are particularly sensitive to climate fluctuations. more...

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