Stop the Press!

For all intensive purposes, all the dowel's have been turned down. So, what else do I need the lathe for? THE STOPS! Even tough the Ruckpositiv will be blocking the entire keydesk area, that doesn't mean I skimp on the details. So, I designed a simple stop design in the computer and will attempt to lathe something similar for the model. Today, I tried three of them. The first two were done the same way, starting from the collet and moving away from it. The last one, I started away from the collet and moved toward it. The dowel size is 1/8" and it is turned down to 1/16".

Made in the order from top to bottom.

In the end, I like the last one the best. Let's hope I can get them somewhat consistent. The keydesk area of the model is the very last part of this project that will brings everything together. So, I got A LOT of time until then. More will be posted about these stops as time goes by.

Starting to Come Together

I made some good progress this weekend. The top and bottom bases have been cut to shape. Likewise, the pipe guide was cut to get it's circular shape. Next weekend, I will drill the holes in them.

TOP: All four bases for the pedal divisions. BTM: Pedal pipe guide's ready to be drilled.

Since those bases are finished. I was able to do a dry fit of all the exterior pieces. I must say, it got me very excited for what is to come. As the subject says...it's starting to come together!

Not shown are the two inside supports for the general structure of the pedal division

Stock

Another successful weekend. First, all the dowel stock that I have measured and cut to length has been turned down. This now comes to a grand total of 52 pipes that have been turned down and mouths have been sanded into the front of the dowel. All these pipes are ready to be sealed, primed and painted. Below are pedal pipes. The majority of the Oberwerk pipes make up the rest of that 52 total. However, there are still many that need to be cut, measured, and turned. That will be this week.

If you look closely, you can see where I sanded in the mouth of the pipe

Today, all the stock for both pedal divisions have been cut. I have a love-hate relationship with power tools. Ever since high school, I was the one who designed stuff and others would build my creation. Thankfully, I have my dad's expertise and skill to assist when it comes to the physical construction of this model. I'm learning something every step of the way.

UL: Pipe Guide - LL: Pedal Base - CTR: Sides - RT: Inside support

Both the pedal base's and the pipe guides still need to be cut to shape. However, that is all the raw stock for both pedal divisions. This project is moving right along!

Great Start!

All the parts for both pedal divisions have been measured and drawn onto various pieces of wood. I did not have enough time today to actually cut them out. For the top and bottom base for this division, I went "old school" and got out my old drafting equipment and drew the piece the same way I drew it in SolidWorks. I just pray that, when everything gets cut out, everything fits together!

I also measured and cut to length most of the pipes for the Oberwerk division. With the stock I had, a few were cut for the Ruckpositiv division. Below is what I have for the Oberwerk. The very center pipe will be above the console. It is 1/2" in diameter and 10" high.

It is hard to tell in this image, but the mouths are indicated by the lines from the bottom of the pipe.
I have a lot of dowel's to turn down in the lathe!

So it Begins!

Today was a huge step forward. About 90% of the wood used for the entire pedal division has been purchased. At the same time, my dad has pulled out some of the dremel tools that he used to build many things when he was a kid. They should serve me well.

L-R: Hand Dremel Tool; Table saw; Scroll Saw

Likewise, I have full access to a lathe at my work. I will have all the pedal pipes turned town after work this Monday. However, I have got to a good start. With the help of the hand-held dremel with a sander attachment, I was able to create the mouths of the pipes that I have already turned down.

Not that bad! The 1/2" and 7/16" dowel's will be turned on Monday.

Let's see what tomorrow brings!

Keydesk Revision

Taking another look at the new keydesk design, I decided to make a few changes. One, I designed a "fancier" stop design. I do have access to a lathe and can turn down dowel's of any diameter. More on the stop design later. Since I might be turning the stops, I went from about 68 STOPS to now 24 stops. I also now have them in a vertical fashion rather than horizontal.

I also changed the music rack dimensions. All this spurred from researching potential decoration against that wall. that the keydesk gets placed.

I have turned the two front 16in pipes. I will be turning down the other pedal pipes tomorrow. Hopefully, this weekend I will get into the preliminary construction of one of the pedal divisions.

Redefining the Inspiration

As I stated, the inspiration for this model was the console my friend gave me. However, I have now decided to go a slightly different direction. The gift is still the initial spark and inspiration. However, I decided to design a more historically accurate key desk for this organ. A key desk is just a term for the desk-like case in which the keyboards and the stop-knobs are contained. The idea for the design, once again, came from the organ at St. Bavo...even down to the seat.

The extended horizontal is there for structural support when placed into the final assembly.

So, good bye to the already made console and hello to the new one! This only adds to this project, the fact that all of it has been designed and built by me. The stops (32 on each side) are 1/16 of an inch. Some will jet out 1/8" for the "canceled" position. Other will extend out 1/4" for the "activated" stops. I'd like to make the stops a little more aesthetic instead of just a flat dowel. Maybe I'll round out the side that you see. I'm not exactly sure yet.
 

There is now a 3-1/8" wall about the key desk. I'm not sure exactly how I'm going to decorate it. I'd like to find an ornate scaled frieze or something decorative to place there. The following sectional view shows how everything is organized.

The actual construction of this entire part of the organ will be last. So, I don't have to worry about it now. First are the pedal divisions. I will be getting the pedal pipes turned down tomorrow. Until then...

Updated Final Isometric View

The Pedal Pipes

Today, I cut to length the pipes for both divisions. The middle pipe is 3/4" diameter and the thickest. This would represent about a 9' diameter on a 16' pipe which I think would be right. From there, I just tried to (proportionally) fill the chamber.

Diameters from Center back (symmetric): 3/4", 5/8", 5/8", 1/2", 7/16"

After cutting them all to 16 inches, I needed to mark where the mouth would be, which is where I will start the taper of the pipe.

Notice the pencil markings where the mouths will be located

As far as HOW I'm going to turn these things down. I will need a lathe, obviously. I'm hoping that I'll be able to use one where I work. I will find that out tomorrow.

The Pedal Grill Work

I started with what probably is the hardest part of the model, the ornate grill work that will be used for the pedal division. I first needed a pattern. So, I took various vector images and put them together in Photoshop and came up with this:

Add caption

The flat line is the base. So, this view would be the top grill. Now, the hard part. How do you make something like this that can also be wrapped around a (approx) 4"  guard? I first tried it on 1/16" balsa wood. I  should have know that there would be issues. It was starting off good, but it cracked half way in would took off the top flourishes.

I stapled the pattern onto the balsa wood

I then remembered that Michaels sold a 1/64" thin birch plywood. So, off I went, bought a piece and tried it again with much success. However, after cutting out the design, my hand was killing me.

It still needs some cleaning up. However, I'm setting the grill work aside for now. I will eventually paint this shiny gold and then try wrap it around a 4" diameter guard which it will be attached to. I've heard of wetting it or playing the wood before steam to help bend the wood. Well, that will be another adventure and another post.

The Model

I designed this project with SolidWorks, a 3D CAD modeling software that I have been using as a draftsman for years. I started with AutoCAD to get a 2D general layout and then moved to SolidWorks. After all the pictures and messing around with different dimensions, I knew what I wanted. Without a doubt, two big pedal divisions on either side. Why, well...it's just cool.

To my knowledge, none of the North German organs had any 32' pipes let alone displayed in the facade. The long pipes with the Haarlem organ are 32' in length. I decided to keep with the Schnitger design and have the dual pedal divisions with 16' pipes. So, with the scaling factor, they would be 16" long. After this, I started on the Oberwerk division, or the facade I would place above the console. The model would also need a Ruckpositiv as well. So, the project model will look something like this:

Isometric View

Front View

The Ruckpositiv will hang approximately 1.75" lower from the ground floor. The total dimensions will be around 22.00" x 20.75" x 11.44". Growing up, I had build many plastic model kits and model rockets. I have never attempted such a project like this. Yet, I feel the timing is right for such an endeavor. I currently have the time, money and resources to take on such a detailed project. So, I figured, why not?!

Not everything is in this 3D model. The final color scheme and splendor will be models off of the Haarlem organ. This will include the deep red case, silver pipes, gold grill work and various angels and statuary.

I will first work on one of the pedal divisions.

In the Beginning

It all started with a gift I had received from a friend of mine. He found this small organ console at an antiques store. I was so happy that he had found such a rare and unique piece. It sat displayed in my room at the college seminary amongst the random organ pipes and statue of Bach.

Now I am back home and I had placed this organ on my desk at work. During lunch one day, I thought to myself, "it would be cool if this had pipes to complete the entire package." Well, now that I'm back in the engineering field (for the time being), I have the software and access to stuff that would make it possible for such an endeavor. I became obsessed with this project. It consumed my mind. Where do I start?

First, I figured out and decided upon the proper scale ratio. The console model is roughly scaled to a 1 inch to 1 foot ratio. Second, I start looking at various pipe organ to get inspiration. What better inspirations than the North German organs of old. Organ designed by Arp Schnitger and played by Bach himself! I took such organs as inspiration:

St. Jacobi Church, Hamburg

Martinikerk, Groningen, The Netherlands

...and others. Yet, there was another organ, not by Schnitger, that I find so very beautiful. It is the Christiaan Müller organ at St. Bavo Church in Haarlem, The Netherlands.

The Great Organ of Haarlem, The Netherlands

With these organs as inspiration and the little knowledge of designing and constructing a facade of pipes around this organ, I began the design and research process. The intention of this blog is to document and share my design and construction process. I am open to comments. Let's see what happens!