In the Wind. . .

Make me an instrument.

I have been involved in the world of building musical instruments since I was about twelve years old as the organist of my home church, where my father was rector, was the harpsichord and clavichord builder Carl Fudge. On occasion, he brought one of his instruments to the church for a special performance, and at that tender age I was fascinated by the concept of playing an instrument you had built yourself. I have thought about that continually in the past fifty-plus years, so my feelings and perceptions have become more sophisticated, but I know I was in awe of Carl’s skill as both instrument maker and musician. Visiting his workshop, I was further enthralled, I started taking organ lessons, and my life’s path was set.

Longtime readers of this column will recognize that one of my favorite subjects is writing about one’s relationship with one’s instrument. In his book Violin Dreams (Houghton Mifflin, 2006), Arnold Steinhardt, first violinist of the Guarneri Quartet wrote:

When I hold the violin, my left arm stretches lovingly around its neck, my right hand draws the bow across the strings like a caress, and the violin itself is tucked under my chin, a place halfway between my brain and my beating heart.

Lovely, isn’t it? What a poetic description of a musical relationship. But his next sentence throws most of the rest of us under the bus.

Instruments that are played at arm’s length—the piano, the bassoon, the tympani—have a certain reserve built into the relationship. Touch me, hold me if you must, but don’t get too close, they seem to say. . . . To play the violin, however, I must stroke its strings and embrace a delicate body with ample curves and a scroll like a perfect hairdo fresh from the beauty salon. This creature sings ardently to me day after day, year after year, as I embrace it.¹

In that light, I imagine Steinhardt would equate organists with truck drivers, sliding onto the bench, flipping a switch to turn on a ten-horsepower motor, and playing the instrument by remote control, twenty, fifty, or a hundred feet away.

I hope he likes it.

Nearly thirty-five years ago, my siblings, mother, and I commissioned a local artist to paint a picture of the red barn behind our parents’ house on Cape Cod in honor of dad’s retirement. We sent her photos of the barn, and she visited there several times in secret. The painting was to be unveiled at “the party” in front of family and friends, and there was an air of excitement, but when the cloth was removed there was silence. It did not look like our barn. The proportions were akilter, and the shadow of a nearby tree fell across the grass and the barn’s wall in a way no shadow could exist under the sun. It was a stunning moment, a much better story now than an experience then.

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I have just reread John Marchese’s book The Violin Maker (Harper Collins, 2007), which follows the commissioning and construction of a new violin for Eugene Drucker, violinist of the Emerson String Quartet. (Drucker and Philip Setzer have equal billing, swapping “first chair” duties back and forth.) Drucker had commissioned the legendary luthier Sam Zygmuntowicz of Brooklyn, New York, to build an instrument to complement the Stradivari instrument that he uses in most performances, but which has a temperamental “personality,” especially when the quartet’s travels take them from one climate extreme to another in a short period. The Strad is slow to recover.

Marchese provides plenty of background information including biographical data about Guarneri, Stradivari, and the other Cremonese luthiers. He spent countless hours with both Drucker and Zygmuntowicz, interviewing them and observing them in the workshop, teaching studio, and concert stage. As Sam chose the wood for Gene’s violin, Marchese related stories about the harvesting and aging of wood; luthiers have collections of pieces of maple and spruce that have aged fifty years since they were harvested and milled. The stability of such aged wood is essential to the luthier. We learn of Sam’s apprenticeship and education as a luthier, how he was privileged to take detailed measurements of a dismantled Strad, and how he created a detailed map of the various pieces of the fiddle, measured to the thousandth of an inch. We hear him speaking with and addressing his colleague luthiers at conferences and restaurant tables. Throughout the book, I could hear the undercurrent: “I hope he likes it, I hope he likes it, I hope he likes it.”

Spoiler alert: Sam finished the violin in time to present it at Gene’s fiftieth birthday party amid excitement and congratulations. Gene plays the instrument for his friends, uses it in concert, and practices on it. He swaps back and forth between the new instrument and his trusty Strad. He wants to love it, but just cannot get there. Ultimately Sam acknowledges that he failed to captivate Gene with the new instrument. I recommend this book to anyone who owns and cares for a musical instrument, and to anyone who builds those instruments.

A bargain at twice the price

Nowhere in Marchese’s book is the actual price of a Zygmuntowicz violin stated, but a quick internet search at least implied to me that it is around $100,000. That is about the price of a new Steinway “B,” the seven-foot piano so prevalent in teaching studios and smaller recital halls. A Steinway “B” weighs nearly 800 pounds—the instrument costs $125 per pound or about $9 an ounce. A Zygmuntowicz violin weighs about fourteen ounces, about $7,143 per ounce. By comparison, think of the $15,000,000 Strad at $1,071,429 per ounce.

As a pipe organ builder, I marvel at the idea that a fourteen-ounce violin might be worth $15,000,000. You can build a mighty pipe organ for that amount; in fact few organs have ever cost that much. And does that mighty organ weigh 100,000 pounds? It is a bargain at $150 a pound or $9.38 an ounce. Why would anyone want to buy a violin when they could have a pipe organ?

Let’s buy a pipe organ.

When an orchestral musician purchases an instrument, whether new or “experienced,” it is a personal transaction. The musician is choosing and paying privately. At Eugene Drucker’s level, the price can be a family sacrifice. That money might have gone toward a vacation home or a boat, but the serious musician cannot function without an instrument of high enough quality to inspire his creativity.

The purchase of a pipe organ is typically a community event. When an organ shows signs of failing or when people within an institution advocate for a new instrument, a committee is usually formed to study the situation. Many of these committees engage consultants to inform and advise their work. Organ companies are solicited for proposals, a budget is established, a decision is made, and the hard work begins: raising the money.

The iconic four-manual, seventy-five-rank Flentrop organ in Saint Mark’s Cathedral in Seattle, Washington, was purchased for $165,000 in 1965. In today’s economy, that is about enough money for the copper 32′ Prestant that dominates the façade. The same organ today would cost something like $2,000,000. A three-manual organ with forty stops is likely to cost $1,000,000. That is a lot of money for a congregation to raise, and regardless of the price per pound, it is a lot of money for a small community of people to pay for a musical instrument.

I like to compare that process with a tennis club deciding to build a swimming pool. A few members come up with the idea on a hot afternoon, the elected leadership gets involved, and contractors offer estimates. Perhaps the membership would be assessed to raise some of the money; perhaps members would be solicited to make donations; perhaps there would be a mortgage to be offset by increased membership dues. Whether it is a tennis club building a swimming pool or a church commissioning a pipe organ, there would likely be a parliamentary process of proposing, discussing, and voting, except in those institutions with authoritarian leadership.

I have long believed that the easy part of the process is building the organ. With decisions made and money raised, an organ builder receives some of that money and gets to work doing what he knows how to do.

I hope they like it.

My comment about building an organ being the easy part notwithstanding, it is a complex task. Where do you start? What is it going to sound like? A point of departure is the determination of scaling of the organ pipes and the wind pressure. The length of organ pipes is pretty much given by the physics of musical tone. To produce low CC, the lowest note of the keyboard, on a unison stop, the speaking length of the pipe from mouth to tuning point is eight feet. The question is, what should the diameter of the pipe be? Are you hoping to achieve a brilliant “baroquey” sound with narrow scales, a lush romantic sound with wide scales, or something in between? Higher wind pressure translates easily into more powerful tone, though there are plenty of examples of low-pressure organs with bold voices.

You can study examples of organs in comparable buildings, measuring the scales and other dimensions of the pipes, and maybe altering the numbers for slightly smaller or broader scales. Some organ builders are brilliant at imagining the tone of a particular scale within a building and designing the rest of the voices to be compatible with the first. For a more certain study, it is increasingly common for an organ builder to bring a portable organ with wind supply and a collection of sample pipes of different dimensions allowing him to compare different scales and wind pressures. It is an expensive process involving travel, lodging, and shipping the equipment and supplies, but if the organ has a million-dollar price tag, it is a modest investment. There is no substitute for producing actual tones in the actual acoustical environment.

Think of the myriad individual projects that make up a completed organ. Artisans are building windchests, reservoirs, keyboards, consoles, wind conductors, mechanical or electric actions, casework, ladders, walkboards—the list can seem endless. And what about ornate decorations like pinnacles, pipe shades, and putti?

Like Sam Zygmuntowicz choosing the wood for a new violin, the organbuilder is on a constant search for good materials. I remember my mentor John Leek in Oberlin, Ohio, in the 1970s purchasing a rare log of boxwood seven or eight feet long and eight inches in diameter for making the sharp keys of his organs and harpsichords, and gorgeous European beechwood for harpsichord bridges and nuts (the slim rail ahead of the tuning pins that lifts the strings off the pinblock). He ordered them through his friends at Flentrop Orgelbouw in Zaandam, the Netherlands, who shipped them to Cleveland in the sea-going container that delivered the brilliant Flentrop organ for Trinity Episcopal Cathedral in Cleveland. Each time we set out to make a set of keyboards, we lopped a piece off that boxwood and milled it into those familiar tapered shapes.

John Boody of Taylor & Boody organbuilders in Staunton, Virginia, specializes in harvesting trees and sawing lumber for their instruments. His appreciation of the beauty of wood allows the artisans there to choose ideal boards for special places. Gorgeous woodgrain patterns on organ benches, around keytables, and casework is a hallmark of their instruments, and John’s care with quarter-sawing and drying the lumber produces especially stable material. In 2009, Wendy and I visited John and Janet Boody as part of a trip to Washington, DC, and Thomas Jefferson’s Virginia home, Monticello. We stayed in an apartment above John’s sawmill and saw the stacks of dried oak boards that would become the case of the new organ at Grace Episcopal Church in New York City.

George Bozeman, another of my mentors, held the concept that wind is the fuel we burn to make organ tone. Any pipe organ has a complex system to produce wind pressure (the blower), transport it to reservoirs and windchests (wind ducts), and regulate it to an exact and steady pressure (reservoirs, also known as regulators). “Bellows” is a term universally used to describe reservoirs/regulators, but I understand a bellows produces wind pressure, as found in the hand-pumped organs of earlier years, or the bellows next to your fireplace. A reservoir stores pressurized air, and a regulator regulates the pressure with internal valves that allow air to flow to the windchests only when the organ is being played and wind is being consumed. Both reservoir and regulator refer correctly to those components of a modern organ wind system, as the pressure is created by an electric blower. Steady, reliable pipe speech relies on steady, reliable wind pressure.

There are two basic types of structure for pipe organs. Some instruments have interior “skeletons” of wood or steel that support windchests, reservoirs, expression boxes, and the ladders and walkboards necessary to reach them all. Others are supported by their free-standing cases. The upright styles of the lower case support the impost, the heavy frame that includes the bases of round or pointed towers. In the case of the Flentrop in Cleveland I mentioned earlier, the impost was by far the heaviest single part of the organ, and the core of its structure. The upper-case panels and styles fit into mortices in the impost and in turn supported the majestic tower crowns. The Pedaal and Hoofdwerk windchests sat on the impost.

In either type of construction, the musical stability of the instrument is a direct factor of its structural stability, especially with mechanical key action, as any motion in the structure affects the adjustment of the action. Organ pipes must be supported to stand perfectly vertically, especially when the pipe metal is soft, as gravity will grab any leaning pipe and try to pull it to the ground. Reed pipes need special support because they are skinniest and weakest at the bottom of the resonator where it intersects with the pipe’s boot. Any organ builder or technician can tell stories about larger reed pipes collapsing on themselves, sometimes breaking free of their supports and crashing down on neighboring pipes.

The proof is in the pudding.

With beautiful wood chosen, accurate actions built and adjusted, wind system regulated and free of leaks, it is time for the pipes. It is a magical moment when an organ produces its first musical tones in its new home. Sometimes we let people in the church know when we expect to sound the first notes. We have already had the excitement of turning on the blower for the first time, experiencing the organ coming to life. People gather, a rank of pipes is placed in their holes, and an out-of-tune hymn is played. After thousands of hours in the workshop, days or weeks of heavy lifting, and precise fitting, the heart of the enterprise comes clear.

What about Eugene Drucker’s reaction to his new instrument? Will the new organ be all everyone hoped for? The local organist will have the strongest reaction, the choir and other musicians who will use the instrument follow suit. The people in the pews will have their opinions. In 1982, John Leek and I installed a new organ we had built at Saint Alban’s Episcopal Church in Annandale, Virginia. The previous organ was a nondescript “asparagus patch” of exposed pipes with little stature; our instrument had a tall case of oak and walnut with classic pointed towers and moldings and shiny façade pipes. We delivered the organ on a Sunday afternoon, and by the following Sunday the case was standing, giving the impression of being complete. John and I sat in the pews as the congregation filed in, found their seats, and craned their necks to see the new organ in the rear balcony. In the quiet of the moment, a young girl cried out, “I liked the old one better.”

Notes

1. Arnold Steinhardt, Violin Dreams (Houghton Mifflin, 2006), 5.

Let’s hoist a few.

On September 24, 2023, Alyson Krueger published an article in The New York Times under the headline, “My Running Club, My Everything,” telling of the culture of running clubs in New York City in which twenty-five or more people gather at a specified meeting place and run together for four or five miles. She described an outing of the Upper West Side Running Club that met at the American Museum of Natural History (Central Park West at Eighty-First Street) where members ran a loop around Central Park and wound up at the Gin Mill on Amsterdam Avenue at Eighty-First Street, one block west of the museum. I chuckled as I read because the Gin Mill is a favorite after hours haunt of the Organ Clearing House crew. I wonder how many of you reading this have sat there with our guys?

The Gin Mill has a happy hour routine with discounted drinks, and if you are anything like a regular and the bartender knows you, it seems as if you are charged by the hour. Your glass gets magically and repeatedly refilled, and the closing check is a nice surprise. I have spent quite a few evenings there, but our boots-on-the-ground crew has spent dozens. In 2010 the crew spent most of the summer hoisting organ parts into the chambers at the Cathedral of Saint John the Divine, followed by hoisting pints and other concoctions at the Gin Mill. Numerous subsequent projects have allowed reunions with the friendly staff there—friendly to good natured partyers, but hard on bad apples.

Since so many of our projects involve hoisting organ components in and out of balconies, towers, and high chambers, I spend a lot of time talking with scaffolding vendors around the country. I have first-name relationships with reps in a dozen cities, as well as with our personal representatives from national scaffolding vendors. We own several electric hoists, including one with a 100-foot reach purchased for that job at Saint John the Divine that can hoist a 2,000-pound load 100 feet in two minutes with a soft start and stop. A multiple-week job like that means that someone has held a finger on the up or down button for dozens of hours. We like to ship our own hoist across the country because specialized rental equipment like that can be hard to find and in poor condition. In a usual setup, the hoist is hung from a trolley that rolls on an I-beam so a heavy load like a four-manual console or ten-stop windchest can be lifted clear of a balcony rail, trolleyed out over the nave floor, and safely lowered. Safely for the console, safely for our crew.

The bells, the bells

Wendy and I left our apartment in Greenwich Village on the heels of the pandemic and moved early last year to bucolic Stockbridge in western Massachusetts, about five miles from the New York border. Our house is three doors up Church Street from Main Street where stands the granite Children’s Chime Tower on the Village Green that is shared by the First Congregational Church. After we moved in, we were delighted to learn that we can hear the largest bell ringing the hour, every hour, from the house—no more wondering what time it is in the middle of the night.

The tower was built in 1879, the gift of David Dudley Field II, son of David Dudley Field, pastor of the Congregational Church, and his wife, Submit (really). David II was a prominent New York politician and attorney who represented William Magear “Boss” Tweed in his Tammany Hall embezzlement trial. (Tweed died in prison.) David II dedicated the tower to his grandchildren, stipulating that the chimes should be played every day from “apple blossom time to first frost.” His grave is in the Stockbridge Cemetery, just across Main Street from the Chime Tower. My grandfather was rector of Saint Paul’s Episcopal Church in Stockbridge when I was a kid, and I remember sitting on that green with my grandmother at picnic suppers listening to recitals on the chimes. The music was simple as there are only eleven bells, but since it was more than fifty years ago, I remember it as grand. That tradition continued until recently when the timber frame supporting the chimes was deemed unsafe due to an infestation of carpenter ants.

The big bell continued to ring every hour until a storm caused a power failure last spring, stopping the clock at 2:16. The clock was not reset after the storm, leaving us wondering about the time during the night. At the last town meeting, the citizens approved rebuilding the chimes with a new steel frame, refurbishing the chimes’ playing action, replacing the roof, and re-pointing the stone work.

I was returning to Stockbridge last week from our place in Maine and saw a large crane set up next to the tower. I went home, unloaded the car, walked back to the green with Farley the Goldendoodle to see what was going on, and I found three men from the Verdin Company of Cincinnati, Ohio, preparing to hoist the bells back into the tower. They had removed them earlier in the week, placing them on a flat-bed trailer owned by the town so they could be driven to safety overnight at the public works yard a half-mile away. The new steel frame was in place, and they were hoisting the bells with their new striking mechanisms back into the tower.

In the twenty months since we moved to town, we had only heard the largest bell as it tolled the hours, but now, as the people from Verdin were putting things together and testing the new actions, I heard all the bells for the first time in more than fifty years. At least one of the technicians knew how to play a little so a few hymns and a couple children’s songs wafted up the street to our house. Before they left town, they set and started the clock, freeing it from 2:16 to cover all 720 minutes of the twelve-hour cycle. The morning after the first night of tolling the hour, I was walking Farley a few minutes before 7:00 and ran into our neighbor Marty with Brody the Labrador at the poop-bag kiosk across from the tower. When the bell tolled the hour and we were chatting about the return of the bells, Marty told me that Stewart across the street used to play the chimes and was looking forward to volunteering again when the rest of the work on the tower is complete and the chime goes back into service. I suppose I will, too.

Doing it the old-fashioned way

After Wendy and I visited Florence, Italy, in May 2023, I wrote about the hoisting equipment designed by Filippo Brunelleschi for the construction of the dome of the cathedral there. He had won the design competition in 1418, and construction started in 1420 on what is still the largest unsupported dome in the world. Brunelleschi’s hoisting gear was powered by oxen walking on a circular treadmill on the floor of the cathedral, a rig that was a lot messier and required more maintenance than what we use on our job sites. He made use of blocks and tackle, the same as used to handle the rigging of sailing ships. It is fun to picture workers hauling hay into the church to feed the oxen, and I suppose there was a poop-bag kiosk there also.

The real genius of Brunelleschi’s hoist was the crane at the top that could transfer stones weighing thousands of pounds laterally to every spot in the circumference of the dome. In the world of rigging, it is one thing to hoist a heavy load vertically; it is a very different challenge to move horizontally from under the hoisting point.

We marvel at ancient feats of lifting. Stonehenge in Wiltshire, England, is believed to be between four- and five-thousand years old. It includes some thirty stones, some as heavy as twenty-five tons. The stones came from a quarry sixteen miles away—simply bringing them to the site was effort enough. In most American states, the weight limits on tandem axles of commercial trucks are between 25,000 and 40,000 pounds. Rhode Island has the highest limit, 44,800 pounds, which is about the weight of one of the stones at Stonehenge. The Grove crane that was helping my friends from Verdin hoisting bells is a robust machine with a fifty-ton lifting capacity. The engineers and laborers at Stonehenge would have been pleased with help from Gary the crane operator.

We visit iconic churches in Europe built in centuries past and admire their seventeenth- and eighteenth-century organs. The monumental organ completed in 1738 by Christian Müller at the church of Saint Bavo in Haarlem, the Netherlands, has 32′ pipes in the pedal tower. As modern organbuilders, we know how much work it is to handle things like that. Those eighteenth-century craftsmen worked very hard.

I was twenty-one years old when my mentor John Leek and I helped a crew from Flentrop in Zaandam, the Netherlands, install the three-manual organ at Trinity Episcopal Cathedral in Cleveland, Ohio. The organ has a beautiful twenty-five-foot mahogany case topped with a massive crown with heavy moldings that stands on a pedestal balcony something like fifteen feet above the floor. The balcony is shallower than the organ case so when you are up on top, you look straight down to the floor.

There is a polished 16′ Principal in the façade, and come to think of it, we installed that organ using technology and equipment similar to that used by Brunelleschi, lifting everything to the balcony and into the organ using a block-and-tackle with hemp rope. Looking back, it would have been a lot more pleasant had anyone thought of using nylon rigging rope like you find on a modern sailboat because that hairy, prickly hemp was hard on our hands. The heaviest piece of the organ was the impost frame with the huge moldings that form the bases of the case towers and the rigid structure that connects the lower and upper cases. I suppose it weighed around 1,500 pounds; so instead of oxen, there was me and a young guy from Flentrop pulling on the rope. We were much neater and easier to maintain than Brunelleschi’s oxen. My sixty-seven-year-old shoulders and back could no more do that kind of work now than fly me to the moon.

To lift the big shiny façade pipes up to the case, a co-worker picked up the top of the pipe and climbed a ladder from the nave floor to the balcony as others moved the toe end toward the ladder, bringing the pipe to vertical. I wore a leather harness around my waist as if I was carrying a flagpole in a parade, we placed the toe of the pipe in the cup, and I climbed the ladder, toe following top as the others above me balanced and guided it into place. Today I stand in a church gazing up at the organ, remembering doing that work, incredulous. I am not half the man I used to be.

I have been with the Organ Clearing House for nearly twenty-five years, watching my colleague Amory Atkins set up scaffolding and hoisting equipment on dozens, even hundreds of job sites. There is still plenty of hustle to the work, but the I-beams, trolley, and electric hoist all supported by steel scaffolding make for a much safer and less strenuous work site.

Making the impossible possible

When I was running the Bishop Organ Company in the Boston area in the 1980s, we had a releathering project in the large organ of one of Boston’s great churches. As usual, we started the job with a string of heavy days disconnecting organ components covered with decades of city grime and removing them from the organ for transportation to our workshop. After we had wrestled a particularly awkward and heavy part down the ladders and out of the building, one of my employees announced that now he thought he understood organbuilding. “It’s squeezing into tiny spaces to remove screws you can’t reach, to separate a part of the organ the size of a refrigerator that’s covered with mud and sharp pointy things and carrying it down a ladder next to a Tiffany window.”

He was right. A big manual windchest might weigh 800 or 1,000 pounds, more for a large console. If we are planning to dismantle or install a Skinner organ that has one of those wonderful electro-pneumatic harps, we might plan an entire day to handle that single specialty voice—they are big and heavy and include row after row of little prickly things that dig into your hands, arms, and shoulders. When I hear a harp in service playing, recital, or recording, my mind jumps instantly to the titanic struggles I have had moving them. They sound so ethereal in a lofty room, but they are pugnacious bulky brats to handle.

The thrilling rumbles of big 16′ and 32′ stops do not happen anywhere else in music, but again, my mind jumps to the herculean task of moving such things. The pipes, racks, and windchests of a 32′ Double Open Wood weigh many tons and will fill half of a semi-trailer. One of the marvels of the pipe organ is the idea that a single pipe might be approaching forty feet in length including pipe foot and tuning length, weigh close to a ton, and can produce only one musical tone at one pitch at one volume level. What a luxurious note.

When I meet people at social events, they are invariably surprised when they learn about my work. “A pipe organ builder. I didn’t know there were any of you left.” Another common comment is someone remembering the organ looming high in the back of the church and if they ever gave it any thought, they assumed that it was part of the building. Not so. Every organ in every building anywhere in the world was put there intentionally by craftsmen. They had to figure out how to mount and secure each heavy component. Think of the sprawling sixteenth-century organ case at the cathedral in Chartres. It gives the impression that it is somehow hanging from the stained-glass windows, but 500 years ago, those workers built scaffolding clear up to the clerestory windows and hoisted and lugged the heavy woodwork and huge pipes to their lofty spots.

Twenty years ago, we were delivering a three-manual organ to a church in suburban Richmond, Virginia. There was a big organ case with polished façade pipes, five large windchests, all the machinery and ductwork for the wind system, seventy or eighty eight-foot pipe trays full of nicely packed pipes, the console, and all the mysterious looking bits and pieces that make up a full-sized pipe organ. Parishioners volunteered on a Sunday afternoon to help unload the truck, and by day’s end the sanctuary was jam packed with carefully made, expensive looking stuff. I had worked with the church’s organ committee and governing board to create and negotiate the project and knew several of the people involved very well. After the dust had settled that evening, one of them came up to me and commented, “John, it wasn’t until this moment that I understood why organs cost so much money.”

Doo-dads

In the late 1970s and early 1980s I lived in a four-bedroom house in the rolling farmland outside Oberlin, Ohio. I had just graduated from Oberlin, was working for the local organbuilder John Leek, and was director of music for a big Presbyterian Church in Cleveland. The house was part of an eighty-acre farm, and like most similar properties in the area, the fields were rented by a farmer who worked a total of about 1,500 acres in the neighborhood. It was typical to rotate corn and soybeans year by year, because their effect on the soil is complementary. Around the house, there were three or four outbuildings including a large barn that I remember as being in better condition than the house. The house had a natural gas well, pretty unusual for many people, but common there in those days. After all, now we know it as fracking country.

Our neighbors Tony and Claire-Marie across the street had a similar property with a neat house, an enormous barn, and fields that were rented by a farmer. They were friends of the Leeks from church and lovely, considerate people. Tony ran an excavating business and used his barn to store and maintain his huge pieces of heavy equipment. Occasionally, Tony invited me to help him with a repair project. I do not think he really needed my help but knew that I would be interested, so I would spend a Saturday with him doing things like changing the wheel bearings on his Caterpillar D-9 bulldozer.

That machine was over twenty-five feet long, fifteen-feet wide, and weighed over 100,000 pounds. You don’t just jack it up, pull out a tire iron, loosen the lug nuts, and pull the wheel off. He had a homemade hydraulic jack made from parts taken from old construction equipment. The hydraulic pump came off an excavator and was driven by the power-take-off of a farm tractor. The lug nuts were three inches in diameter (his sets of socket and open-end wrenches went up to five inches), and he used a backhoe and a hoisting strap to lift the wheel off the machine. I was a young apprentice, the proud owner of a new set of Marples™ chisels (I still have them and use them regularly), and I had never seen such an ingenious caper. Because of my career in organbuilding, I have had a lifelong fascination with tools and, as Tony realized, I would always be interested in seeing something new to do with tools.

Watching Tony make that heavy work look easy by using the right tools influenced my work with organs. It was not long after that time that I was helping to install a large three-manual tracker organ in a high organ loft. We centered the floor frame properly, but when the case started getting tall, we could see that it was not going to center under the peak of the vaulted ceiling. We used hydraulics to move the entire organ with case, windchests, reservoirs, keyboards, and actions, budging it to the right about an inch-and-a-half. (Don’t tell anyone.)

When we were done with the wheel bearings, we started the D-9 (the starter motor is a forty-horsepower diesel motor), climbed on board, he backed it out of the barn, and let me drive it around in a circle in the big gravel apron. I had another experience running heavy equipment when the farmer who rented our fields was harvesting corn, and I got to run the combine for a couple rows. Glad I didn’t have to parallel park it.

A man and his tools

As more than forty years have passed since my heavy-equipment-operator days, I have downsized to a small private workshop which is the three-car garage attached to our house. I have a table saw, drill press, and band saw left from my big shop days, and shelves and drawers full of countless hand tools and odds-and-ends. I have a terrific woodworker’s workbench, the maple job with built in vises and bench dogs, and I have a sturdy well-lit, double-length workbench where I do most of my work. Wendy and I are thinking about enlarging the laundry room (sometimes called the mud room) that shares a wall with my shop, a wall covered with shelves. We were standing there tossing ideas around, and she commented that I might just get rid of all that stuff. Quickly and defensively, I pointed out the house jacks.

Why does an organbuilder need house jacks? When releathering a reservoir, you get to the step where the pairs of ribs are glued to the top frame and the whole assembly is glued to the body. You cut and glue on the eight leather or rubber cloth belts and let the glue set overnight. In the morning, you have to open the reservoir by lifting the top, as if it were filling with wind. All that freshly set glue and nice stiff material has to be convinced that this is a good idea, and the reservoir is on your workbench, so you are lifting it to chest level. That is a perfect use for a small house jack. I prop the jack up on blocks and pump the hydraulic handle. You can also use a house jack lying sideways to budge an organ an inch or two to the right.

But more to the point, remember when our daughter Meg wanted to convert the little shed out back to a pottery studio and we realized that one of the posts had rotted? Remember how her husband Yorgos and I jacked up the corner of the shed and sunk a new post into the ground? That’s why I need a house jack.

What is that next to the house jack? An ultrasonic cleaner, a little tub with a metal basket and a dial on the front. I use it to clean brass parts like reed tongues and shallots, cabinet hinges, escutcheons (look it up), and the fancy little brass doo-dads that organbuilders like to use for trim pieces, specialized controls, and the like. Parson’s Sudsy Ammonia™ is a great solvent. Fill up the little tub, fill the basket with your parts, and Bob’s your uncle. Oh, and anytime you have metal jewelry that needs cleaning . . . .

There is a big stainless-steel double boiler, the thing you ladle soup from in a cafeteria line. It’s on the shelf next to the glue pot. Hide glue comes in dry flakes or crystals. You mix it with water and heat it in the glue pot. You keep adding more water or more glue as you work to keep the consistency the way you want it. You can also put cloves of garlic in a cheesecloth bag and let it soak in the hot glue—it’s supposed to keep the glue from getting moldy, and it makes it smell a little better. When you are working with that glue, you need to have a hot, wet rag nearby to clean off excess. I can fill the double boiler and use the thermostat to keep the water just exactly as hot as I can stand putting my hands in, so I always have a good hot, wet rag. Oh, and when we have a cookout, I can clean it up and serve chowder from it.

There is a beat-up old steam iron. For the same reason I use hot water to clean up while gluing, applying heat is a big help when ungluing something. Crank up that old iron and heat up the rubber-cloth strips on an old reservoir, and voilà, off it comes, smelling like burned rubber. You can put heavy paper between the iron and the rubber to keep it from sticking, but it is hard to avoid gumming up the iron with melted rubber, so when it cools, I hold the iron on my belt sander to clean it off. This maximizes the awful smells you can extract from old rubber cloth. You should not take this iron into the house and use it on white linen. There is a household benefit, however. When it finally stops working, I will steal the iron from the bedroom closet and buy a new one for pressing clothes.

A popular meme says that you only need two tools, WD-40™ and Duck Tape™. If it’s supposed to move but doesn’t, use WD-40™. If it isn’t supposed to move but does, use Duct Tape™. As a professional organbuilder, I find that pretty sophomoric. But Wendy wanted to know why I need so many spray bottles. WD-40™ is great stuff, and it smells better than burned rubber. But it is oily, so you might want to use silicone for some applications. That is what I used on the sliding doors in the living room the other day. If you have WD-40™, why do you need Marvel Mystery Oil™? Simple. I love the pepperminty smell of it.

Goof Off™ comes in spray bottles, aerosol cans, and squeeze bottles, different dispensers for different situations. It is a terrific solvent for Duck Tape™ residue, or any kind of adhesive. The last time I used it on a service call, I was removing old chewing gum from under the keyboards of a distinguished organ. C’mon, people. And that is what I used to remove that nasty tar from the fender of the car. Works on stubborn windshield bugs, too.

3M 77 Spray Adhesive™ is terrific for gluing felt and leather together to make valves or for covering pallets. Spray that stuff on both surfaces, and according to the instructions on the can, “make bond while adhesive is aggressively tacky.” The can bears the warning,

Extremely flammable. Vapors may cause flash fire. Vapors may cause eye, skin, nose, and throat irritation and may affect the central nervous system causing dizziness, headaches, and nausea. Intentional misuse by deliberately concentrating and inhaling the contents may be harmful or fatal.

At least the valves do not come unglued. When Wendy finished that beautiful woven tapestry and wondered about fixing it to a piece of fabric for framing, that’s what I used. I feel fine.

My two favorite general cleaning agents are Murphy’s Oil Soap™ and Simple Green™. Both are biodegradable, and both are really effective. Both can be used full strength or diluted in water. Murphy’s is terrific for cleaning old woodwork, Simple Green™ cleans just about anything. I have two spray bottles for each, one diluted by 50%, the other full strength. You can also pour a bit in a bucket of water. And they both smell great. And there is some of each under the kitchen sink.

There must be thirty heavy plastic cases. Get rid of half of them?

• A set of dado blades I use to make the table saw cut wider. I used them to make that bookshelf.

• A propane torch that is good for light metal work. That is how I bent that piece of iron to hang the birdfeeder on the deck.

• A tap and die set that cuts threads on metal wire or rods (outies) or inside holes (innies) from one-eighth to one-half, in coarse and fine threads.

• A set of ratchet socket wrenches, both English and metric, with quarter-inch, three-eighths, and half-inch drives with extensions. The last time I used that, I was tightening all the hardware on your loom because you said it had gotten wobbly.

• Many sets of drill bits.

* One goes from one-eighth to half-inch, graduated by sixty-fourths.

* One has about a hundred bits graduated by the numbers and letters of the American Wire Gauge (AWG).

• Say you are using bronze wire that’s .064′′ as an axle in tracker keyboard action parts. You want the wire to be tight in the hole in the part that moves, and barely loose in the mounting hole. Use the .059′′ bit (#53) for the tight hole, and the .067′′ bit (#51) for the loose hole.

* One is metric from two to twenty millimeters, graduated by tenths.

* One is Forstner bits from a quarter to two inches, graduated by eighths, especially useful because they drill flat-bottomed holes, and since they are not guided by a central pin, you can drill overlapping holes.

* One is “airplane” bits from one-eighth to three-quarters, graduated in eighths, especially useful every few years because they are eighteen-inches long. I don’t need them very often, but when I do, nothing else will work.

* One is spade bits from three-eighth to two-inches, best for making very sloppy holes in soft materials, and for spraining your wrist. I do not use those very often.

* Okay, okay. I have two of the AWG sets, and two of the sixty-fourths sets. There are a few bits missing from each, and one of the drawers over there has replacements bits for every size.

• Digital calipers that read in fractions or thousandths of an inch, or hundredths of a millimeter. That is how I know that piece of bronze wire was .064′′.

• Another big set of socket wrenches that does not include metric sizes. That is the one we carry on the boat. I forgot to put it on board this summer.

• Caddies with assorted screw sizes that I bring to installation sites, so I never have just the size I am looking for.

• You get idea. The next time, I will write about why there are eight toolboxes full of tools. Sometimes they are all in the car at once.

That huge rolling steel cabinet with drawers that looks like it belongs in a gas station? In my previous shop, all my hand tools hung on purpose-made racks. There is not enough wall space for that here, so I bought this. In the drawers, from top to bottom:

• hinged tools like pliers and wire cutters. I used this big Channel Lock™ wrench last week to fix the drain for the outdoor shower;

• open-end wrenches;

• measuring tools like squares, scribes, miter gauges, calipers, micrometers, folding rulers, steel rulers;

• cutting tools like dovetail saws, Exact™ knives and blades, scissors, rotary knives and blades (for cutting leather and felt), small carving tools, razor blades, and the three beautiful leather knives that John Leek brought me from Holland in 1976;

• screwdrivers;

• that set of Marples™ chisels;

• pneumatic accessories like blow guns, detachable couplings, and assorted valves for inflating things. That is how I blew up the soccer ball. And remember when friends from New York were worried about their tire pressure? There is the gauge and valve;

• staple and pop rivet guns, staples and pop rivets;

• arch punches for cutting round pieces of leather and felt, or for cutting round holes in leather and felt. My set goes from one-eighth to three-inches;

• rotary bits for routers, cutting plugs, deburring holes;

• multi-spur bits—the big dangerous looking ones for drilling the holes in rackboards, dozens of them from a half-inch to three inches.

That cabinet serves me well and is big enough for the available space, but I admit to having tool-chest-envy when I walk through the big stores and see the jobs as big as a bus that have charging stations for power tools and mobile phones, refrigerators, and mirrors. What a great idea. You can tell which mechanic has a mirror in his toolbox because his hair is always combed.

It is easy enough to explain all these tools and supplies, especially when I can argue their domestic usefulness. How does anyone get by without an ultrasonic cleaner? But I also have boxes by the dozen with cryptic markings. “Schlicker Console Parts” is full of the little toggles that set stops on pistons, salvaged when I installed a solid-state combination action in a Schlicker console. Anyone needs some, I’ve got them. “Austin Coils” are the “electro” part of the Austin electro-pneumatic note motors. Anyone needs some, I’ve got them. “Skinner Toggle Springs,” “Misc. Peterson,” “Large Slide Tuners,” “Spare Ivories,” “Reed Organ Reeds,” anyone needs some, I’ve got them.

It’s not just an organ shop.

There is a cabinet full of flowerpots and gardening supplies and tools. There is a cabinet full of stockpots and lobster pots, overflow from the kitchen. There is a bag of life jackets, ready for winter storage. There are a half-dozen boxes full of spare parts for a sailboat, an outboard motor, a couple anchors, and lots of nautical line. You never know when you’re going to need a piece of line. Or an air horn. Or Schlicker combination parts. It would be aggressively tacky to think that I would get rid of them.

Made right here

The organist of my home church was a harpsichord maker, and visiting his workshop was my first exposure to building musical instruments. I guess I was something like ten or eleven years old so my impressions may not have been very sophisticated, but as I think back over more than fifty-five years in the business, I must have been impressed. I started taking organ lessons when I was twelve, and sometime soon after that a mentor took me to an open house at the original workshop of the Noack Organ Company in Andover, Massachusetts. There I got an early eyeful of what goes into the instrument I was learning to love.

Since that first encounter with the art of organ building, I have been privileged to visit many organ builders—from large and impressive operations like Casavant Frères and Schantz to tiny one-person shops. There are elements common in the smallest and largest shops. For example, every organbuilder has a table saw. I like to say that organbuilding can be described as the art of knowing where to put the holes, which means each workshop has a drill press and an impressive collection of drill bits. There are thousands of drill bits in my workshop, ranging in size from a few thousandths of an inch or tenths of a millimeter to three-inch behemoths for drilling large holes in rackboards. You have to hang on tight when one of those bad boys is turning in the wood.

Every shop has a setup for cutting and punching leather. I use the plastic cutting boards you buy in fabric stores for cutting long strips of leather and a rotary knife like a pizza cutter, and I have a heavy end-grain block capped with half-inch-thick PVC for punching the thousands of leather circles and buttons needed for the leathering of pneumatic actions and valves.

Over my half-century experience with organ shops, there have been countless innovations in the world of tools. When I was an apprentice working with John Leek in Oberlin, Ohio, we turned all our screws by hand. Dismantling a large electro-pneumatic-action organ for releathering was like a triathlon, working over your head with a screwdriver turning thousands of screws to release bottomboards, pouchboards, stop action machines, and windlines. We had forearms like Popeye. Later we had the first electric screwdrivers, which were simply drill motors that had to be plugged in. At first, they were too powerful for driving screws into the soft wood of organ windchests, but soon adjustable clutches were introduced allowing you to set the torque of the machine to avoid stripping the threads of too many screws. Still, these had power cords that were a nuisance to keep away from the pipes of the windchest below where you were working. It was always a Mixture.

When cordless drills and screw guns were introduced, the battery life was not great. You would need to have three or four batteries dedicated to each tool if you wanted to run it for a few hours, changing and charging the batteries as you went. Today there is a wide range of powerful twenty-volt tools available with remarkable battery life and torque enough to sprain your wrist. I have switched my entire assortment of professional and home maintenance tools to the 20V DeWalt system, including chainsaws and weed whackers, delighting that I no longer need to keep gasoline around the house. I can run that weed whacker for an hour on a single charge, long enough to get around our large rural lawn. And the screw guns just keep going and going.

Was it twenty years ago when Computerized Numerical Control (CNC) machines were becoming popular? These technological marvels can be programmed to quickly produce complicated woodworking projects. One of the first uses of CNC machines in organ shops was the drilling of windchest tables that have rows of different sized holes for each stop. A drawing is fed into the computer, and the machine selects the bits and drills away. I remember standing at the drill press, drilling the holes in rackboards, toeboards, and sliders for a new organ, changing the bits by hand for each different hole size. A long row of boards stood against the wall nearby, and I drilled the 7⁄16-inch holes in all of them, then would change the bit to half-inch and start again. (I followed the rule of drilling the smallest holes first, knowing that if I made a mistake and drilled a hole or two too many with one bit, it would be easier to correct than if I had started with the big holes.)

When I first saw CNC machines in operation, it seemed that you would need a group of NASA scientists to operate one. Today, knowing some of the very small shops that had adopted them, it is apparent that pretty much anyone can learn to run one. CNC machines crank out windlines, action parts, reed blocks, pipe shades, and pretty much any part of an organ made of wood. CNC machines are also used for making things from metal, mass producing hundreds of identical parts or producing single complex fittings.

Making metal organ pipes is one of the magical parts of our trade. To do that, especially to make alloys and cast sheets of molten metal, a shop needs an expensive, complex setup that requires a lot of space, so most organbuilders buy pipes made to their specifications by specialized pipe-making firms. Still, several shops have all this equipment, and it is a thrilling process to witness. Metal ingots are melted in a cauldron over high heat, with the different metals, usually tin and lead, weighed carefully as the alloy is specified by the tonal director. The cauldron is mounted near the end of a long narrow table, typically with a stone surface, and the table is fitted with a sled. The metal is ladled into the sled, and two workers push the sled steadily down the length of a table, leaving a thin sheet of the molten brew on the stone. Stare at the gleaming surface for a few seconds, and watch it glaze over as the liquid turns to solid.

Casting metal for organ pipes is a process that has been in use as long as we have had organ pipes. The Benedictine monk, François-Lamathe Dom Bédos de Celles (1709–1779) included beautiful engravings of this process in his seminal book, L’art du facteur d’orgues (The Art of the Organ-Builder), published between 1766 and 1778. When the metal has set and cooled, the sheets are rolled up. They are then either planed by hand or on a huge drum to the specified thickness. Some pipe makers hammer the metal before forming the pipes, duplicating an ancient process that compresses and strengthens the metal. Then they cut the metal to create the different parts of an organ pipe, rectangles for the resonators, pie-shaped for the tapered feet, and circles for the languids. They are formed into cylinders and cones and soldered together to form the pipes. Every organist should find a chance to witness this incredible process.

Potter at work

Harry Holl’s Scargo Pottery in Dennis, Massachusetts, was a common summer evening family outing when I was a kid. We all loved the woodsy setting with a row of potter’s wheels under a corrugated fiberglass roof where we would stand watching Harry and his colleagues, many of whom were apprentices, create beautiful dinnerware, mugs, vases, and bowls. Like the mysteries of casting organ metal, it is a bit of magic to watch an artist place a blob of clay on a wheel and poke and prod it into a vessel. Watching a blob become a bowl is like watching a flower open. The craft is exacting when making a set of plates or bowls. Each is a hand-made individual, but they will stack better in your kitchen if they are pretty much the same size, so the potter uses a caliper to measure the height and diameter of each piece to form a set.

When Wendy and I moved into our house in Newcastle, Maine, in the winter of 2001, my parents gave us a set of eight large dinner plates made by Harry Holl with deep blue glaze in a rippling pattern, which we still use frequently. There is a large table lamp on my desk, and the house is scattered with the lovely artworks from Scargo Pottery that we eat and drink from each day.

Harry worked mostly with ceramic clay that emerged white from the kiln. There is a particular beach near Scargo Pottery with distinctive black sand that Harry liked to blend with his clay, giving his pieces a speckled effect that shows through the glaze. His sense of shapes and his love of his material made him a great artist. His daughters Kim and Tina run Scargo Pottery now, long after their father’s death.

Those summer outings typically had a pleasant coda, as we would pass an ice cream shop called Sea Breezes on the way home. Getting into the car at Scargo Pottery, we would pipe up a sing-song chorus, asking if “Sea Breezes are blowing.” My father was a sucker for ice cream, so it was always a safe bet.

Will it float?

Around us in Maine there are several boat yards that build custom wooden boats. Like any artisan’s shop, they are a delight to visit, and as a life-long organbuilder to whom straight and square are virtues, the absence of straight lines in the hull of a wooden boat is mind-boggling. The hull is nothing but voluptuous curves in every direction, from front to back (forward to aft), top to bottom (rail to keel), and side to side (beam to beam). Boat builders place huge planks into steam-filled vessels to soften them and carry them to the side of the boat where they are fastened to the ribs with huge bronze screws (which don’t corrode in salt water) or wooden pegs. When I worked with John Leek, we used the same steaming process to make the bentsides of harpsichords.

When a hull is complete and decks and interior are fitted out, the boat is launched, a test that no organbuilder ever has to face. I marvel that the never-before-immersed vessel floats flat and level. I guess it is comparable to the marvelous moment when you turn the wind on in an organ for the first time. Both the boat and the organ come to life at their first moments of usefulness.

Back to its maker

In the spring of 2013, Wendy and I set sail in Kingfisher from Marshall Marine in Padanaram, Massachusetts. She is a Marshall 22, built there in Padanaram in 1999. We had purchased her the preceding fall and spent the winter imagining and planning our maiden voyage to bring her to her new home in Newcastle, Maine. Our son Andy then lived in nearby New Bedford, Massachusetts (home of the largest fishing fleet in the United States). We left one of our cars in Newcastle, and Andy dropped us off at the boatyard and took care of the other car while we were at sea.

Our trip took six days and five nights and covered more than 250 miles. We had mapped out the route and reserved dock space or moorings in different marinas for each night. We ate dinner onboard most evenings and reveled in showers at the marinas. It was one of the great adventures we have shared as a couple. A friend raced out in her motorboat to snap a photo of us entering the Damariscotta River. Stepping onto our dock and walking up the back lawn seemed like a miracle. Sleeping on solid ground for the first time in six days, I rolled out of bed onto the floor.

Each summer since, we have set aside weeks for “cruising,” when we provision the boat for days and nights on the water and explore the infinity of the famous rocky coast of Maine. We have anchored in picturesque harbors and on remote islands. After the huge learning curve of handling the boat on the first trip, we have mastered Kingfisher, learning when we can push her, when we should reef the sail against heavy wind, and just how high can we “point” against the wind to round that reef without tacking. We have several friends in the area who have waterfront houses, and one of our favorite outings has been to sail to them for rollicking dinners and slumber parties. And one of the great things about a boat is that you can go places otherwise unreachable.

Last summer, nudged by the pandemic, we left Greenwich Village, moved into our new home in Stockbridge, Massachusetts, and quickly made a gaggle of new friends. Tanglewood, the summer home of the Boston Symphony Orchestra, fifteen minutes from home, would be less of a summertime conflict if they only held concerts when it was not good sailing weather in Maine.

When our local boatyard hauled Kingfisher out of the water last fall, I asked them to touch up the varnish on the brightwork, the teak pieces that trim the fiberglass hull whose finish is ravaged by constant sunlight and salt. He touched it up, all right, and sent me a bill that recalled the saying, “She looks like a million bucks.” It was a surprise, but we took it as a hint. What better time to offer her for sale than when she looks like a million bucks?

Two weeks ago, Kingfisher went by truck back to Padanaram, and last week I stopped by Marshall Marine to deliver the sail that had been at a sail maker for winter cleaning and repair. Geoff Marshall, who runs a workshop with seven people building those lovely boats, is also the broker from whom we bought her, and he walked me through the different buildings, talking about the various boats in different stages of completion. Here is one that is just getting started, and here is another that is due to launch in a few weeks. The new owner is just as eager to see her in the water before Memorial Day as the organist is to play the new organ on Easter Sunday.

When I watched Kingfisher drive up the hill away from Round Pond, Maine, on the back of the truck, I felt as though a piece of me was dying. How we have loved the time onboard with family and friends, and with Farley the Goldendoodle curled up on the deck. There is nothing like the taste of the first sip of coffee in the morning or of a gin and tonic after a long day of sailing, and there is nothing like the thrill of bending the wind to get you to a party.

Frequent readers will remember that I have written many times about the common philosophies of sailboats and pipe organs, that both are human attempts to control the wind. Kingfisher is leaving our family, but I will always have a little salt water in my blood. You haven’t heard the last of it.

Shipping and handling included

Wendy and I live in a building with about two hundred households. We are mostly anonymous neighbors; just a few fellow residents are casual acquaintances. The people we chat with the most are the other dog owners, and we are more likely to know the dogs’ names than their owners’. Farley the goldendoodle is a cheerful and friendly guy so he attracts a lot of attention in the elevators and lobby.

Living in close proximity to that many people, we are constantly reminded of what a click-and-ship world we live in. Adjoining the building’s lobby is a large package room lined with shelves ten feet high where the doormen sort hundreds of parcels. Since Amazon started same day delivery in the city, as many as a half-dozen delivery trucks stop each day.

Twice a week, mountains of trash and recyclables are piled on the sidewalks including thousands of collapsed cardboard boxes tied with twine. Along with the boxes, we routinely throw away bales of bubble wrap, tons of Styrofoam peanuts, and miles of strips of air-cushion bladders. It can be a wicked nuisance dealing with a big carton of peanuts. It is especially annoying when they get charged with static electricity and I cannot get them off me. And for goodness sake, keep them away from the dog.

I am thinking about packaging today because I am just finishing an organ project in my little workshop in Maine, starting to take things apart and getting them ready for shipment. Yesterday, I went to a storage locker I rent nearby and loaded several empty pipe trays into my car. The standard size we make at the Organ Clearing House is eight-feet by two-feet by eight-inches deep. They are larger than those made by some other companies, and when they are full, they are heavy, but we think they are just right. Low EE of most 8′ stops fits in those eight-foot trays, so we also make some ten-footers to hold the biggest four pipes. We can get the biggest four of an 8′ Principal into one of those, or the biggest four of two 8′ strings.

My car is a Chevrolet Suburban, big enough to hold an eight-foot rowing dinghy with the doors closed. A guy at a local boatyard called it a Chevy “Subdivision.” When there is no boat inside, I can get four eight-foot trays in the car with the doors closed.

I took the pipes off the windchests and laid them out in order on a big work surface. I lined the bottom of each tray with a ¼-inch thick Styrofoam sheet (we buy it in 250-foot rolls, perforated every foot, three rolls come in a “tube”). I opened a carton of clean 24-inch x 36-inch newsprint, and started wrapping pipes. With experience, you get a sense of how many pipes should be in a package. I use several sheets of newsprint at a time to weave between six-foot pipes so they cannot bump against each other. Going up the scale, getting to around tenor F of an 8′ stop (a three-foot pipe), each pipe is wrapped individually. After middle C, two to a package, then three, then maybe as many as six or seven treble pipes. When I am putting several pipes in a package, I roll it each time so there is paper between each pipe, and I fold the ends over opposite sides to increase the padding. My favorite local butcher does the same thing with the marvelous sausages he makes. A piece of tape holds the package closed, and the bundles are lined up in the trays. If the pipes are not very heavy, I can put a couple layers in a tray separated with Styrofoam.

My personal shop is a three-car garage that adjoins our house, and this is a tiny organ. It started as an M. P. Möller Double Artiste, and we are adding a third three-rank division to make a total of nine unified ranks. The user interface is a large three-manual console, also by Möller but from a different organ, equipped with a fancy combination action. It is to be a practice organ for a school of music, providing students with a platform for working on the complex Romantic and symphonic registrations that are so popular these days. This will be a simple shipment, nowhere near a full truck. The only complication is that we will be driving it over the Rocky Mountains in mid-winter.

That load will include eleven trays, nine with pipes and two with odds and ends, bits and pieces (the stuff Alan Laufman called “chowder”), console, bench, three windchests, two “expressive” cases including shutters and shutter motors, three wind regulators with windlines, a blower, the biggest pipes of a nicely mitered 16′ Bourdon (too big for trays), and the rest of the flotsam and jetsam it takes to make an organ. I am guessing the load will weigh around 6,000 pounds including the trays and packing materials. We will also be carrying a new residence organ built by a colleague firm, as its new owner lives in the same western city. We are always happy to throw another organ on the back of the truck if there is space.

§

When we estimate the cost for dismantling and packing an organ, we consider the number of person-days and crew expenses like travel, meals, and lodging. We decide whether we will need to rent scaffolding and set up hoisting equipment, and we figure how much we will need in the way of packing materials. An important variable is the tray count, which varies as much by the style of an organ as it does by number of ranks. If we are packing an organ with mechanical action built in the 1970s with low wind pressure and small scales, we can figure on two or three ranks per tray. (A usual four-rank mixture easily fits in a single tray. You just have to be sure you label the packages so you do not mix up the ranks.) If we are packing a heavy Romantic organ like something built by Skinner, it is more like two or three trays per rank. A big fat Skinner 8′ French Horn can fill four trays!

Based on long experience, we run down the printed stoplist of an organ and note how many trays we will need for each stop, and I enter the totals for eight-foot and ten-foot trays into a spreadsheet that spits out the lumber list. A four-by-eight sheet of 7⁄16-inch OSB (Oriented Strand Board) makes two tray bottoms, and it takes two ten-foot pine 1 x 8s to make the sides and ends. When we dismantled an eighty-rank Aeolian residence organ on Long Island (imagine that!), we figured we would need 160 eight-foot trays and 40 ten-footers, and I sent this list to City Lumber in Long Island City, New York:

120 4′ x 8′ sheets OSB

320 10′ 1′′ x 8′′

80 12′ 1′′ x 8′′

120 8′ 1′′ x 2′′ strapping (10 bundles) for battens on tray tops

1,680 feet ¼′′ x 2′-wide Styrofoam (7 rolls)

50 pounds 15⁄8′′ coarse thread drywall screws

The bill was $5,277.33, including delivery, and we gave the driver a $50 tip.

When we have finished dismantling an organ, the packed trays go on the truck first. A standard semi-trailer is 100-inches wide inside so we can stack four piles wide. If we make stacks of ten trays each, we can cap the stacks with sheets of plywood and put 16-foot metal bass pipes up top. The big metal pipes are wrapped individually in Styrofoam for protection. Interior height of the trailer is 110 inches. Four trays wide and ten high, that is forty trays for each eight feet of trailer. The trailer is 53-feet long—240 trays is a truck full. That is less than the tray count for the wonderful Skinner/Aeolian-Skinner organ at the Cathedral of Saint John the Divine in New York City.

When we are packing an organ that large, the trays are just the beginning. Think about the organ’s biggest pipes, like that 32′ Double Open Wood Diapason. The biggest pipe is more than 35-feet long, and about two-feet square. I guess that pipe weighs 1,500 pounds and by itself makes a big dent in an empty trailer. Three 32′ ranks (Diapason, Bourdon, and reed) and the windchests of that huge organ fill truck number two. Reservoirs, shutters, expression motors, tremulants, windlines, ladders, and walkboards fill truck number three. And number four brings the console, frames, expression box panels, blowers, and 8,000 pounds of chowder.

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Most of the trucks with box trailers that you see on the highway are carrying loads of goods that are all the same size, packed on pallets whose dimensions are calculated to exactly fill the trailer’s interior space. Paper towels, potato chips, mattresses, and tableware are packed in boxes whose dimensions exactly correspond with the pallets. A truck backs up to a loading dock, and a forklift runs in and out carrying pallets, two or three at a time. The trailer is nothing but a metal and fiberglass box. There are no hooks, cleats, or straps to fasten the load. There is no need, because the load assembles to the same dimensions of the trailer, and it takes fifteen minutes to pack.

We engage special commodity trucks, which come with lots of special equipment. There are highway bars that span the interior by clicking into vertical tracks on the trailer walls and support plywood floors, so we can build a second story that safely carries smaller components. There are ramps and hydraulic tailgates because we almost never have the luxury of a loading dock, and a standard complement of twenty-dozen quilted furniture pads. We specify that we will need six or eight hours to load the truck as they typically charge extra when it is more than two hours. The trays go into the truck fast and neat, and the rest of the organ is like a ten-ton game of Tetrus. Because no two parts of the organ are the same size, the pallet-and-forklift equation does not work at all. Each piece of the organ is wrapped with pads as it enters the truck. At the other end of the trip, it is a huge job just to fold all those heavy pads, and the drivers are always fussy about making neat piles.

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Most of the organs we move fit into “Bobtail” trucks, the standard single-body box trucks we can rent from Ryder or Penske. A usual two-manual organ fits in a single truck. Forty years ago, when I was first in the organ business, there was little in the way of regulation controlling the type of trucking we do. Today, the Federal Motor Carrier Safety Administration makes us jump through regulatory hoops. If we are carrying an organ that we have owned and are selling to a client, there is no problem. But if we are carrying an organ that belongs to someone else, like a church or school, especially if we are crossing state lines, we have to be ready with our DOT and MC (Motor Carrier) numbers whenever we encounter a weigh station on the highway. That makes us an official trucking company, and I receive a lot of a gear-jamming junk mail that has nothing to do with organs.

In 2008, we were engaged to bring an organ to an important church in Antananarivo, the capital of Madagascar, and we would include a dozen pianos in the shipment for a couple churches and orphanages I had visited. I found a moving company in Maine that had a barn full of surplus pianos, rented a truck, loaded them up, and started down the Maine Turnpike. As required, I stopped in the weigh station where the state trooper asked me, “What are you carrying?” “Pianos,” I answered. “Where are you taking them?” My sense of the ridiculous took control, and I answered, “Madagascar!” He directed me into a parking area where three troopers spent a half hour trying to find something wrong with my paperwork, with the truck, with its required emergency flares and reflectors, anything they could think of.

We have worked with many drivers over the years, mostly owner/operators who contract with central dispatchers. Richard Mowen was a special favorite, a wiry little man with a huge Peterbilt tractor. He had replaced the Caterpillar diesel engine after two million miles, and he traveled with a little dog in the cab. Many commercial drivers only come and go from big warehouses with loading docks, while our work in churches around the country is anything but predictable. It may be a narrow cross street in Manhattan or a winding dirt road in a rural village. Richard could put that rig anywhere. It is much more difficult to back a semi-trailer when you have to go backwards to the right, because that is the blind side. It was fun watching him figure his angle, nudging the tailgate right where we wanted it.

Richard loved carrying pipe organs. He moved many organs for us, and we recommended him to a number of colleague companies. He considered organs to be a specialty, and he was a treasure. Sadly, he had a heart attack that took him off the road, but he is still around. We miss his great work and thank him for his terrific service to our industry. Richard left us with one of the best driving tips ever. “I can drive down that hill too slow as many times as I want. I can do it too fast only once.” We will remember that next month when we are driving down the far side of the Rockies.

Then there is the guy who was dispatched to drive an organ from New Haven, Connecticut, to Reno, Nevada. With the truck loaded, we were chatting and joking on the sidewalk by the church when the driver mentioned that it was a good thing we were not shipping the organ to Canada, because he had been busted for transporting firearms illegally and was not allowed to drive there anymore. I called the dispatcher and requested a different driver.

Through all the shipments over the years, there was one that involved significant damage to the organ. We packed and loaded an organ in New York City and sent it off to Los Angeles. The shipment was to be received by a crew from the European company that built it, and they would install it in the church there. The truck arrived as scheduled, and when they opened the doors, they found a mess of broken woodwork and organ parts. There was a language barrier between the organbuilders and the insurance adjuster who viewed the damage. When they told the adjuster that they might have packed things differently, he interpreted that they were saying we had been negligent. Knowing that was not true, I got the adjuster to agree to reconsider if I went to Los Angeles to present a case.

That shipment had an unusual stipulation. We were required to remove the organ from the building in New York before a certain date, and the delivery could not happen until after a certain date, which meant that the organ would be in the truck several days longer than the actual travel time, and we had arranged to pay a daily standstill fee. Naively, I imagined that the truck would sit still in a parking lot. It did not take very much digging to learn that the driver had taken advantage of the situation and made a detour to visit family in the mountains of Tennessee. The trucking company admitted that there had been “an incident” on the road, and the insurance claim was paid.

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It is fun to think of the romance of building a fine organ, with dedicated craftsmen working together in a comfortable shop, cutting and milling wood, working leather and metal, building the thousands of individual pieces that combine to create an organ. The next time you are playing or listening to an organ, especially a really big one, give a thought to the physical challenge of taking all those pieces and parts from one place to another. The shipping industry calls it logistics or material handling. I think it is a great glimpse into yet another reason that pipe organs are so special. What other musician can measure the size of the instrument by the truckload?

When a load is complete, paperwork signed, doors locked, and the driver climbs into his cab, we give a classic truckers’ greeting, “Shiny side up!”

Music as community . . .

When I was offered the opportunity of joining the Organ Clearing House during the summer of 2000, I faced a critical choice. In addition to working independently as an organbuilder and technician, renovating and maintaining a gaggle of organs in the Boston area, I was also director of music at a large suburban Congregational church. I knew that the Organ Clearing House would sweep me into a busy travel schedule, and that I would have to make a choice.

That was a difficult decision on many levels. I had developed many friendships over my nearly twenty-year tenure at the church. For the first sixteen years, it was a privilege to work with the senior pastor, a kind and wise man and fellow sailor who preached beautifully and supported the music program vigorously. The privilege diminished after his retirement with a string of short-term successors who ranged from silly to terrible, but I valued my relationship with the choir enormously. We were fortunate to have a superb professional quartet joining the twenty or so volunteers, and we had a blast preparing and presenting all sorts of music from simple unaccompanied hymns to great oratorios with orchestra.

Each Thursday night, we opened our home after rehearsal, and at least half, sometimes all of the choir would show up. BYOB was the order of the day (though we made sure to have extra on hand, just in case), and we would order pizza or some appropriate substitute and spend a couple hours discussing the music we had worked on that evening, projects that various members were involved in outside the church, and simply nourishing our friendships. I have no doubt that the camaraderie of those many evenings enhanced our music-making by building special levels of trust and respect among that cheerful group of musicians.

Almost twenty years have passed since I faced and made the decision to leave all that and join the Organ Clearing House. I do not regret the choice, but I miss the fun and richness of working with that choir. Of all the aspects of playing the organ for worship, I miss most the pageantry of processional and recessional hymns—the movement of the sound of the choir through the building, the relationship between the choir and congregation, the ebb and flow of the poetry, and the wonderful feeling of producing all that acoustic sound to surround, lead, encourage, and inspire the congregation. As the choir mounted the chancel steps and split into the rows of center-facing choir stalls, I loved having eye contact with them as I played and they sang. Sometimes an exchanged wink would remind us of a joke, sometimes we simply reveled in the joy of it.

The living organ

Charles Brenton Fisk (1925–1983) was an innovative and inquisitive organbuilder and founder of the venerable firm C. B. Fisk, Inc. Charlie was revered by his coworkers for his Socratic teaching, inspiring creative thought by posing questions. He famously said, “The organ is a machine, whose machine-made sounds will always be without interest unless they can appear to be coming from a living organism. The organ has to appear to be alive.” I have often written that it is the challenge, even the responsibility of the organbuilder to remove the mechanics from the equation. Practically, it is impossible. Every organ has some elusive click, buzz, or hiss. But careful attention to fabricating techniques and quality control, especially being sure that moving parts are identical in form and function can tame the wild beast within.

Some organs, especially undistinguished organs with electro-pneumatic action, can seem like industrial products with lifeless tone, but when I am working inside an instrument, there is a big difference in the sensations I feel whether the blower is running or not. When the blower is not running, the organ is static and lifeless. When the blower is turned on, I hear and feel the air surging through the windlines, filling the reservoirs and pressurizing windchests. There may be a few creaks and groans as wind vessels fill. The organ gains breath and comes alive.

Organs that are conceived, intended, and built to seem alive are those that can become part of a community of music making in a church. They join the choir in air-driven acoustic musical leadership, that unique type of tone that carries and blends so well.

At one with the machine

In his book, Violin Dreams (Houghton Mifflin, 2006), Arnold Steinhardt, the now retired first violinist of the Guarneri String Quartet, wrote sensually about his relationship with his violin: “When I hold the violin, my left arm stretches lovingly around its neck, my right hand draws the bow across the strings like a caress, and the violin itself is tucked under my chin, a place halfway between my brain and my beating heart.” (page 5)

I have shared this quote in these pages several times over the years. When I first read it, I was touched by his eloquence about the intimacy of his relationship with his instrument, and I wondered further, what about the clarinetist or bassoonist who puts the business end of his instrument in his mouth. It does not get much more personal than that.

Compare that to the organist sitting on the bench at one end of a large room. She draws a simple stop, perhaps the most beautiful Diapason voice on the instrument, and plays a single note. If the organ has tracker action, the motion of her finger has moved a few levers to open a valve, releasing stored pressurized air to move into the pipe and produce tone.

If it is an electro-pneumatic organ, her finger has closed an electric contact (switch) sending current through a wire to an electro-magnet. The energized magnet moves a metal armature (valve), which opens one end of a pressurized channel to the atmosphere. The other end of that channel is closed by a leather pouch with a valve glued to it. When the pressure is released from the channel, the pouch collapses, pulling open the valve. It takes a lot more words to describe simply the motions of an electro-pneumatic action, and if it is a large instrument, there can be many more steps between key and valve including intermediate relays and switching. But in a well-built and well-regulated action, it all happens instantaneously.

That one motion of the organist’s finger sends a single tone across the vast space. It is similar to flipping a switch to turn on a light. But the lively thrill of playing the organ comes in the clever and seamless operation of the machine. Touch a button with your thumb and that single note releases a roar. Hold the note and flex your ankle, and the note gets softer. And to think you have done all this with a single note. Multiply those gestures exponentially, and you create a musical whole with an expressive range greater than that of a symphony orchestra, deftly skipping from one family of instruments to another, combining them, giving them solos, filling the room with complex tones.

Mr. Steinhardt is one of our greatest violinists. He can produce magic from that pound of spruce, producing a kaleidoscope of colors. He can shift from stentorian majesty to nimble coloratura. But Steinhardt’s kaleidoscope is miniscule when compared to the organist shifting from a mighty chorus of Tubas to a distant Aeoline. And the organist’s ability to superimpose a variety of tone colors simultaneously is unique in the world of music. The contrast between a Diapason and a Trumpet is the perfect example. The two voices may have the same volume level, but they are significantly different in harmonic structure. They can be compared one after the other, they can be contrasted, each being given an independent line of music, or they can be combined and played together. And that is just two stops. Multiply that by dozens or even hundreds, and the organist has a seemingly limitless variety of tone available at the touch of a finger. Or thousands of touches of fingers.

And that is where the seamless machine comes in. Recently, a colleague mentioned that he was using a sequence of forty-five pistons for a single decrescendo. What does that statement mean to a knowledgeable organist? First, it must be a huge organ to have that many pistons and enough stops to make that many meaningful changes in a single passage. Second, the organist is seeking a very grand, sweeping effect. Third, the organist is putting in a lot of work to prepare. Does it take an hour, two hours, or more of practice time to create such a sequence? Did he need to have a friend present to share in the listening as he made decisions? And we can assume (or hope) that this monumental organ is in a huge acoustic space. And that is one of the singular aspects of playing the organ—creating vast tonal structures in vast acoustic spaces. (I was right on all counts. It was David Briggs working on registrations for his new transcription of Bruckner’s Seventh Symphony at the Cathedral of Saint John the Divine in New York City on February 26.)

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A violin typically weighs less than a pound­—400 grams is usual. The luthier labors for months with a half dozen pieces of wood, each of which weighs a few ounces. We weigh pipe organs by the ton, and the process of building an organ involves thousands of hours of managing hundreds of components, some of which weigh as much as a ton. You see that big tower crown with moldings and carvings, sitting on top of a forty-foot organ case? And how did it get there? That’s right. People put it there. Notice how it is just a foot or two from the ceiling arch? And what does that mean? Right. There could be no hoisting point above it. People put it there without mechanical assistance.

How do we build a ten-ton machine whose mechanical presence can vanish under the fingers of an artist? Here are a few of the myriad issues to be considered by the organbuilder.

Architectural design

The excellent monumental organ should claim a commanding architectural presence in its surroundings. The organ relies on the building for the projection and blending of its tone, and the symbiotic relationship should include visual harmony. In that sense, the organ is the mouthpiece of the building.

Tonal structure

If an organ is intended for liturgical use in a large space, it must include:

• a wide dynamic range with individual voices carefully planned so as to allow subtle gradation between different levels of volume;

• enough variety of tone to satisfy the requirements of congregational leadership, expressive accompaniment of solo voices and choruses, festival outbursts, and the realm of solo organ literature;

• multiple keyboard divisions, each with a specific purpose and individual character, and each blending seamlessly with all the others.

Limitless lungs

A mentor and colleague once shared his mantra with me, “Air is the fuel we burn to produce organ tone.” If we are setting out to produce monumental tone in a monumental space, we are going to need a lot of fuel. It takes a hurricane of air to make one big bass pipe go. Once in a while, when servicing an organ, I have occasion to lift one of those big babies from its hole, and let me tell you, until you have experienced ten or fifteen inches of wind blasting through that six-inch hole, you cannot have full appreciation of the amount of energy involved in the speech of that pipe.

Add to that one toehole the hundreds involved in the last fortissimo chord of French toccata, and you might get a sense of what’s going on. A six-note chord with a hundred stops playing equals how many toeholes? A large organ blower might be able to move ten thousand cubic feet of air per minute at whatever pressure the organ is running on. How big is ten thousand cubic feet? It’s fifty by twenty by ten feet. A professional bowling lane is sixty feet long.

The machines and reservoirs that create and store the pressure are accurately regulated to provide pressure at a steady and constant rate. If the pressure varies, so does the pitch and intensity of the tone.

Sensitive mechanics

I have stressed several times the importance of silence of the organ’s mechanical systems. Once again, it is impossible, practically, to make such a complex and monstrous machine disappear. The listener may hear a “thump” from the console during a big registration change, a squeak from an expression shutter, a click from a distant primary valve. The organist and the organbuilder or maintenance technician cooperate to correct and repair those conditions as they arise. I know I have spent hundreds of hours crawling around in organs looking for extraneous mechanical noises. On more than one occasion, it has turned out not to be the organ at all, but a light fixture above the nave ceiling that rattles when low FFF# is played. The last time the bulb was changed, the custodian did not tighten all the screws.

The keyboards are regulated so that all feel alike, and the “strike point” of each is at precisely the same level. All the keys travel the same distance and have the same spring tension and weight.

Windchest actions are silent and consistent. Precision is essential in fabricating the mechanical parts of a pipe organ. Each must have exactly the dimensions, density, and weight in order to ensure that each note performs the same as the rest. The standard for the best pipe organ actions is the repetition rate. In both tracker and electro-pneumatic organs, the action must be free and capable of repeating faster than any human fingers can move. While many musicians assume that speed of attack is essential to rate of repetition, the offending issue is more often the (lack of) speed of release.

With all these factors faithfully executed and carefully balanced, the pipe organ becomes the perfect extension of the musician. It is an acoustic pantograph, expanding the scale of musical thought according to physical settings.

Community spirit

That organ, so beautifully balanced and scaled to its environment, is not only an extension of the thoughts and inspirations of the organist, but for the entire community of listeners and singers. While plant life takes in oxygen and produces carbon dioxide, a transformation that is essential to the balance of life, a pipe organ takes in air and exhausts air. The same air that runs through the works and the pipes of the organ is inhaled by the singers, soloists, choristers, and congregants alike, who in turn produce musical tone in harmony with the instrument. The inspiration and exchange of air enables the inspiration and exchange of musical ideas, emotional responses, worshipful experiences, and the range of human interaction. Those sensations are measured in goose bumps.

The organ in the church where I played last was not extraordinary, but it was a good, solid, pretty complete three-manual electro-pneumatic organ. It was in good condition and everything worked, and the independent voices blended nicely into choruses, with solo singers, the choir, and with the congregation. It was a familiar part of the family, and together we rode its broad back through countless adventures. It was a magic carpet ride with plenty of seats and cup holders. I loved it.