Dear Phillip, I *suspect* you are simply applying too much tension to 
the core wires. But I cannot calculate the tension without knowing the 
winding pitch or spacing of the overwound strings, which is not given in 
your schedule.

IWS wire is excellent for solid strings, but I have not used it for the 
cores of overwound strings because it is softer-drawn than Malcolm Rose 
and is not as strong: so that's one possible cause of problems.

Another comment: you say you substituted .016 inch diameter wire because 
.015 was not available; but that will increase the tension on the string 
unless the winding pitch is appropriately increased. Did you recalculate 
the formula for that note?

If you would kindly supply the winding pitch for each note, I shall have 
a go at calculating the resulting tensions (may take me a day or so) and 
then I may be able to advise.


-- 
Peter Bavington
Clavichord Maker
291 Sprowston Mews
LONDON
E7 9AE
www.peter-bavington.co.uk

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