Hi Pete and List Readers,

It sounds as if you are doing all the logical things, i.e., smaller
motor pulley, reducing accordion travel, disabling crash valve, etc.  I
have occasionally had to take similar steps.  There are two additional
areas you need to examine.

(1) The expression box regulator springs.  Sometimes they are of equal
basic strength, i.e., wound of the same diameter wire.  More frequently,
at least in grands, one spring will have a higher spring "constant"
having been would from larger diameter wire than the other.  Make sure
this stronger spring is on the Theme regulator, not the Accompaniment.
Recognize that the stretched force of these springs determines the
maximum dynamic of the expression box, therefore the collars of these
springs (in your case) should probably be adjusted "downward" so that
their forces are minimized to the extent possible when stretched by the
regulator board's movement.  In extreme cases it may be necessary to
replace these springs with ones having a lighter constant, but, before
doing this, consider the other area of concern:

2) Look to the piano action itself, particularly hammer hardness.  It
really sounds to me as if you should have a qualified piano technician
evaluate the hammers for possible voicing.  _Do not_ attempt this
yourself unless you understand hammer voicing thoroughly, as it is
pretty much a "black art" in my opinion.  Good luck, and let us know how
things turn out.

-John Grant