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In the Wind: casting of metal pipes

Casting a metal pipe

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.

Related Content

In the Wind. . .

John Bishop
An out building

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.

In the Wind . . .

John Bishop
Fisk shop

Making things

Before we moved to New York City, Wendy and I lived in the Charlestown Navy Yard in Boston. Our building had been an electrical warehouse for the Navy Yard, which actively built ships from 1801 until 1975. It is a building that once had forklifts racing around inside, so the ceilings were nice and high. Our living room windows looked across Boston Harbor to the Coast Guard base, the Custom House, and into the heart of Boston, and we had “cocktail chairs” in front of the sixth-floor windows where for ten years of evenings we watched the Wednesday night sailboat races, foolish non-seamen in overpowered speed boats, and the constant flow of commercial shipping including the mammoth Liquid Natural Gas tankers whose captains looked us in the eye from their towering bridges.

The Navy Yard still functions formally as a military base as it is home to the USS Constitution, the Navy’s oldest commissioned warship. One of the oldest buildings in the Charlestown Navy Yard is the Ropewalk, built of heavy granite blocks and completed in 1838, where most of the rope used by the United States Navy was made until it closed in 1970. Imagine the floor plan of a building designed expressly for making rope, over 1,300 feet long and 45 feet wide. That is more than twice the length of the Cathedral of Saint John the Divine in New York City. One of my walking routes included the length of the building that is almost exactly a quarter mile, and I wondered what sort of machinery was used for all that twisting and winding. Take a look at this video to see an antique ropewalk in operation: https://www.youtube.com/watch?v=2M5mo2I2c0Q.

The Maine Maritime Museum is on the site of the Percy & Small Shipyard in Phippsburg, Maine, where dozens of wooden sailing ships as long as 444 feet were built through the nineteenth century. The museum is adjacent to the Bath Iron Works, famous for having launched a new destroyer every twenty-five days during World War II with Rosie the Riveter riveting a river of rivets. Now, the Bath Iron Works is known for producing new Zumwalt Class destroyers.1 The museum includes a diorama of the J. T. Donnell Ropewalk in Bath, Maine, which adjoined Percy & Small and provided the shipyard with rope. When you are building six-masted schooners you need lots of rope, and the ropewalk was a wooden structure some 1,200 feet long with a stationary steam engine at one end to power the equipment. A legend by the diorama shares a quote from The Bath Times in 1883:

John D. Smith of this city, a ropemaker at the J. T. Donnell ropemaking factory, has done a large amount of walking in his life. He is sixty-four years old and has worked at ropemaking for forty-five years working as a handspinner, in which time he has spun 69,940,666 fathoms [six feet] of thread, walking ten miles a day to do this, which in the forty-five years of spinning would aggregate the enormous distance of 140,400 miles [six day weeks for forty-five years]. Of this, one-half the distance has been accomplished walking backwards . . ., the equivalent of backing a distance nearly equal to around the world three times.

Reminds me of the quip about Ginger Rogers, who did everything Fred Astaire did, but backwards in high heels. (Mr. Smith probably didn’t wear high heels.)

Color my world with a spring in my step.

Children have grown up watching Sesame Street since 1969. I was thirteen, and I had just landed my first paying job as a church organist, so I was above “strings and sealing wax,” but fifteen years later the show was a staple for my sons. As a lifelong machine geek, I loved the segments about how things are made, all of which are easy to find online. There is a humdinger about making crayons accompanied by a brilliant musical tone poem. My favorite is “Peanut Butter,” the jazzy flapper-style song written and performed by Joe Raposo that accompanies a tour through a peanut butter factory featuring smiling workers in what look like Krispy Kreme hats pushing the important looking buttons to run the machines. I especially like the shot of a broad stream of peanut butter oozing out of a press and into the pipes that lead to the jars as Raposo sings, “he keeps it pumpin’ through the pipeline like a peanut-butter-pumper should.” What great teaching.

Among the many factories I have toured are a potato chip factory (no free samples but a gift shop at the end), a major brewery (free samples), and an auto assembly plant (no free samples). When I was working for John Leek in Oberlin in the early 1980s, we were building an organ for Saint Alban’s Episcopal Church in Annandale, Virginia, and we planned to make the sliders in the style of Flentrop, double sliders of Masonite, the holes connected with little leather tubes, with hundreds of springs between them to press the two sliders against chest table and toeboard.

No hardware store could have supplied the thousands of identical fine coil compression springs we would need, and we found the Timms Spring Company in Elyria, Ohio, perfectly situated to supply the several large car makers in the area. The company had around twenty employees, most of whom were tool-and-die makers, and the factory was full of machines. Timms would receive an order from a car maker for a million specialized springs, and a machine would be set up to make them that would then run on its own for a week or two gobbling up coils of wire and filling bins with springs.

We brought a sample (probably borrowed from a Flentrop organ we serviced) and met Bill Timms, the third generation of the spring-making family. Bill gave us a fascinating tour around the factory explaining the purpose of each spring being made and gave us lots of free samples. We watched as a toolmaker set up a simple jig to copy our spring by hand and returned a week later to pick up our order.

Organ shops

Visiting a pipe organ workshop is a special treat, educational and eye-popping for both the layperson and the organbuilder. I have visited dozens of shops across the United States, in Great Britain, and in Europe, and while I like to think I know a lot about the building and history of organs, I always learn something fresh. It is fun to compare how different workshops approach common tasks like building windchests and reservoirs, racking pipes, or making wind connections. Different firms have particular products or processes they have developed of which they are particularly proud, different firms have thoughtfully designed console layouts that distinguish them from others, and different firms specialize in different types of windchest actions.

The organbuilding firm of Harrison & Harrison in Durham in Great Britain moved into a new well-equipped building in 1996, where one can pass from one department to another witnessing the deep skills of a venerable firm at work. Immediately upon entering the building, one sees displayed in an elegant frame a cast gold medallion and a letter from Queen Elizabeth II dated November 20, 1997: 

Prince Philip and I are delighted and deeply impressed with the marvelous work of restoration of the fire damaged area of Windsor Castle. Being anxious to show our appreciation of the skill and dedication, which you and others have devoted to it, we have this special medallion struck to mark the completion of the restoration and it comes with our grateful thanks. [Signed] Elizabeth R

The organ involved in the Windsor Castle restoration is a new instrument of seven ranks in the “Private Chapel” built in 1997. Harrison & Harrison has produced a vast list of important and well-known organs including those at King’s College, Cambridge, Durham, Ely, and Exeter cathedrals, Royal Festival Hall, Westminster Abbey, Winchester Cathedral, and Saint George’s Chapel at Windsor Castle. We have all seen several of those organs on television. I especially like the thought that the marvelous organ in Westminster Abbey was built for the coronation of George VI in 1936—imagine the feelings of nervousness, expectation, and pride those organbuilders must have felt. When I visited that workshop in 2016, the organ from King’s College was in the shop for renovation. I got a kick out of noticing the pipe crate labeled “Solo Tuba,” the stentorian tenor melody under a certain verse-six descant ringing in my ears. My visit to Durham included a tour of the H&H cathedral organ with operations manager Jeremy Maritz, setting the standard that one Double Open Wood Diapason is not enough. There’s one on each side of the choir, one of which goes to 32′.

The workshop of Taylor & Boody in Staunton, Virginia, is housed in an old public school building with huge windows and high ceilings, a spacious, airy, and well-lighted place to work. Since the firm was founded in 1979, they have built nearly ninety mechanical-action organs, developing a great reputation for excellent workmanship. Most of their instruments show the influence of the North European Baroque, with tonal schemes that allow lots of versatility. They ensure their own supply of high-quality wood by harvesting carefully chosen trees, cutting them into lumber in their sawmill, and drying them in the adjacent kiln. It is a kick to walk around the yard among stacks of lumber designated for particular opus numbers. When Wendy and I visited there in 2009, we stayed in the apartment above the sawmill and saw the huge oak logs destined to become the wonderful innovative organ for Grace Church in New York City. We have a fond memory of John Boody showing us his “free-ranging” moveable chicken coop and giving us fresh eggs for our breakfast.

Taylor & Boody is one of a number of firms that casts pipe metal to their own specifications. Watching the casting box being pushed down the long table leaving a shining pool of molten metal behind is something special to watch, especially the magic moment a few seconds later when the elixir turns into solid metal. The transformation from liquid to solid is instantly apparent. It seems like alchemy. The idea that freshly cast metal and those huge oak logs would soon be a pipe organ epitomizes the craft we celebrate.

Schoenstein & Company in Benicia, California (the gateway to Napa Valley), mirrors the dedication to quality at Taylor & Boody, building organs in a style worlds apart. They are widely respected for the sophisticated tonal structures with versatile orchestral voices, double expressions, and powerful solo voices, and their elegant consoles are superbly appointed with accessories unique to them. One look at an expression shoe and you know it is a Schoenstein organ. Schoenstein purchased their building in 2004, leaving the 1928 workshop in downtown San Francisco. They have since raised the ceiling of one room to forty-two feet, creating an erecting space, and added a wing for pipe shop, voicing room, and archives. The attention to detail is unparalleled—the company logo is stenciled on the propane tanks of the forklift. Jack Bethards and his skilled staff are working with a clear vision, strongly influenced by the fabled companies of the early twentieth century. The firm has just completed a grand organ with four manuals and seventy stops, including a 32′ metal façade, for the new Basilica of Mary, Queen of the Universe in Orlando, Florida.

Glatter-Götz in Pfullendorf, Germany, is housed in a new facility built for them shortly after the famous Walt Disney Concert Hall organ was completed. When I was there in the fall of 2019, vast fields of sunflowers were in bloom as I drove to the little village. There is a one-story façade facing the street, effectively concealing the two-and-a-half story rear of the building. There is a huge slanted roof covered with solar panels allowing second floor offices at one end of the building and lofty open areas with plenty of space for erecting organs and handling long lumber. You enter at the end of the building where the lunchroom is to the left, the voicing room to the right, a corridor ahead to the workshops, and a long stairway to the suite of offices. All the workspaces have lots of big windows, plenty of clean bench space, storage areas for lumber, and fasteners, leather, and organ parts are neatly organized. There were two organs being assembled when I visited, one for Marietta, Georgia, and another older instrument being renovated for a music school in rural Russia. The next-door neighbor is a farm implement dealer, so a parade of tractors runs back and forth outside.

Paul Fritts & Company occupies an attractive architect-designed (craftsman style?) building in Tacoma, Washington. I visited there in April 2019 with my colleague Amory Atkins (it was Amory’s birthday) while we were installing an organ at the University of Washington. Organs for the First Lutheran Church of Lorain, Ohio, and the Chapel of Hillsdale College in Hillsdale, Michigan, were standing in the shop when we visited. The Lorain organ was complete and ready for shipment. I was especially impressed by their CNC (computer numerical control) router. It is housed in a separate building to separate the considerable noise from the rest of the workshop. It is as big as a bus and capable of drilling entire windchest tables with dozens of different hole sizes, milling the many sizes of wood reed boots, and mitering wood windlines, all by programmed computer control. The machine chooses and inserts bits as necessary and calmly progresses from one task to another while the organbuilders work on other tasks in the workshop across the way. We had a birthday dinner with Paul and college pals Bruce and Shari Shull in Tacoma, then drove back to our hotel in Seattle in a wicked rain squall, crowned by a complete double rainbow. Happy Birthday!

C. B. Fisk, Inc., moved into a new purpose-built facility in 1979. That building has been expanded significantly since, with tall erecting space added, and a large wing containing several department workshops. The first organ to be built and assembled in the new shop was Opus 68, a three-manual, twenty-seven-stop instrument for the Southwick Music Complex of the University of Vermont. Close to ninety new organs have been built in that building, which, like others I have described, is superbly equipped and spacious enough for nearly thirty people to be at work with all the tools and supplies they need.

Charles Fisk founded the eponymous company in 1961 in an old ropewalk building in Gloucester, Massachusetts. C. B. Fisk “lifer” Bob Cornell, who has been with the firm for fifty years, remembers that the ropewalk was actually built for making nets for the city’s fleet of fishing trawlers. (Remember George Clooney and Mark Wahlberg in The Perfect Storm.) There was a twenty-foot-high room at one end where organs could be erected, and an attached structure over 120-feet long where the nets had been made and the various workspaces for the organ company were placed. Bob remembered poison ivy growing through openings in the walls, and that the long floor slanted away from the tall building as the land sank into the nearby bog causing window frames to become trapezoidal. About ten people worked in that shop. The landmark organs for Kings Chapel in Boston (1963) and Harvard Memorial Church (1967) were built in the ropewalk.

What groundbreaking work happened in that shop as the innovative and Socratic Charlie Fisk, with a loyal group of disciples, dug into the history of organbuilding and developed the signature style that has been so influential. The company has now built over 150 organs in distinguished venues all over the world. Those fledgling organbuilders may not have walked 140,000 miles, but they sure changed the content of the industry.

Each of these companies has a well-developed website with photo galleries, opus lists, and workshop tours. Happy visiting. And buy good organs.

Notes

1. Just to show that the Navy can have a sense of humor, the first launch of the futuristic evil-looking Zumwalt class ships was the USS Enterprise commanded by James Kirk. 

Photo:

The Fisk Ropewalk, moving day to the new shop, Charles Fisk loading the van (photo credit: Robert Cornell)

In the Wind: Changing seasons

John Bishop
Follen Community Church organ

Changing seasons

I am writing in early October as the weather in New England is getting nippy. This is the first fall in our new home in Stockbridge, Massachusetts, where hillsides and mountain vistas are ablaze with natural color. We have completed the annual ritual of taking our boat Kingfisher out of the water after our tenth season with her. She is a “catboat”—no, not a multi-hulled catamaran. Catboats were developed as commercial fishing boats in the nineteenth century. They have a single sail with the mast mounted right in the bow so there is lots of sail area for power, and they are easy to handle alone. She is on stands “on the hard” at our boatyard in Round Pond, Maine, and last Saturday Wendy and I climbed aboard to fill tubs with dishes, utensils, pots and pans, bedding, and all the miscellaneous gear that seemed essential when still on the shelves at Hamilton Marine. We had taken most of the food off following our last sail, but there were still a couple bottles of booze in the locker. Nothing tastes better than the first gin and tonic at anchor by a remote island after a long day on the water. Fever Tree and limes are standards on our cruising shopping list.

For years, it has been part of my fall ritual to take our 450-square-foot sail to Pope Sails and Rigging in Rockland, Maine, for its annual cleaning, light repairs, and safe winter storage, but when I called Doug Pope last week to let him know I would be coming, he told me he was retiring and recommended Jenny Baxter who is buying Gambell & Hunter, a sailmaker in Camden, Maine. Jenny has been apprenticing with Grant Gambell for six years and is taking over his shop as he retires. She is about to move into a large commercial space and has purchased Doug Pope’s sail-cleaning equipment.

I drove to Gambell & Hunter’s old shop, which is housed in a barn in a residential neighborhood. Jenny was on the phone with her realtor when I arrived, and Grant came down in his stocking feet to help unload our sail into the shed. When Jenny got off the phone, she came down in bare feet to look over the sail and invited me upstairs to the sail loft, a large room with a spotless open floor, a couple stations with sewing machines, and racks of thread festooning the walls. Organ builders, if you ever need a custom-made rubber cloth windsock made to specifications, you will never do better than with a sailmaker. They know heavy fabric like you know poplar.

Camden is a legendary yachting center and is home to five or six large charter schooners. You can book a cabin for a week or two and sail the Maine coast with crews who prepare clambakes and boil lobsters onboard. Wendy and I have encountered the schooners several times during our cruises. We have seen guests diving off the boats at anchor and paddling kayaks into remote coves, and we have passed the schooners under weigh, their huge sails drawing the beautiful vessels at exhilarating speed. Jenny and Grant are a generation apart and grew up in different regions, but they both came to Camden, Maine, as young people to work on the schooners, serving on crews, running boats, and playing host to guests. They both developed their love of sailmaking while serving on those crews.

As an organbuilder and avid sailor, I have long understood that the two pursuits involve an attempt to control wind. I shared this thought with Grant and Jenny and learned that Jenny played the organ in high school. She assumed the organist position with arms and legs extended on the stool she was sitting on and mentioned how much she loves the Kotzschmar Organ in Portland, Maine. (I have served on the board of Friends of the Kotzschmar Organ for over twenty years.) Here’s wishing Jenny Baxter the best in her new venture, and I am looking forward to seeing her in the spring when it is time to put Kingfisher back in the water.

Stars in your eyes

When I was ten years old singing in the choir in my home church, the organist was a harpsichord maker, and I was captivated by the idea that he was playing on an instrument he had built. Today, I know dozens of people who are passionate about building pipe organs the way Jenny is passionate about sailmaking. I remember feeling special when I was assigned my first task for a teenage summer job in an organ shop, standing in the parking lot with a can of Zip-Strip and some gold-painted façade pipes on sawhorses. I admit that I am less enchanted by that same task today. I remember the adventure of going on the road to install an organ for the first time. I remember the thrill of hearing an organ come to life, turning on the wind for the first time, sounding the first notes, and seeing the glowing faces of the people in the church when they heard the first hymn played on their new organ.

Of course, I also remember difficult and demanding days, furiously heavy days, and disappointments when things would not work or did not turn out well, and I remember that special feeling when I made mistakes. Along with millions of Americans, I grew up watching ABC’s Wide World of Sports on Sunday afternoons, hearing the slogan, “the thrill of victory, and the agony of defeat,” watching a ski jumper’s spectacular wipeout repeated week after week. My mentor John Leek in Oberlin immortalized my apprentice mistakes by nailing them to the wall above my workbench. They were still there when I visited ten years after I left his shop.

That Zip-Strip summer was 1975, and I was employed by Bozeman-Gibson & Company after my freshman year at Oberlin. I was working on the façade for a rebuilt nineteenth-century organ we were installing in a Salvation Army Chapel in Providence, Rhode Island. The chapel was in a newish building that included offices and had some guest rooms where we were staying. Breakfast and lunch were served in the kitchen by an ex-con named Vinnie, pleasant enough, but for dinner we drove across town to the Salvation Army’s men’s service center where we stood in a cafeteria line with what seemed like hundreds of homeless men. It was a good learning experience for a young man from comparative privilege.

During the two summers I worked for Bozeman-Gibson, I helped with organ projects in Providence; Castleton, Vermont; Belfast, Maine; and Squirrel Island off Boothbay Harbor, Maine, which is seven miles from our house in Newcastle, Maine, as the crow flies in water that we have sailed for years. Last summer Wendy and I spent a night onboard Kingfisher at a mooring in Linekin Bay near Boothbay Harbor and sailed around Squirrel, with Wendy listening yet again to my reminiscing about that project forty-six years ago.

John Farmer, who has run his organ company in Winston-Salem, North Carolina, for forty years, and I were working together on the Squirrel Island organ. It was completed in the workshop in time for us to install it in the crossing of the Cathedral of the Holy Cross in Boston, Massachusetts, for a concert of the Handel & Haydn Society during the 1976 American Guild of Organists national convention with Barbara Bruns playing a Handel organ concerto. The one-manual, eleven-rank organ was a perfect fit for that music. The convention ended with AGO Night at the Pops with Arthur Fielder, E. Power Biggs, and the Boston Pops Orchestra playing Rheinberger in what I believe was Biggs’s last public performance. (He died in March 1977.) Boston’s Symphony Hall was filled with two-thousand organists. At the end of the concert, Fiedler faced the audience and said something like, “We thought that you would know some of the words.” The orchestra gave those introductory measures, and the audience swept to its feet and bellowed “Hallelujah” like it’s never been sung before or since.

John and I packed up the organ and drove it to Boothbay Harbor where we loaded it onto the private ferry for Squirrel Island—it took three trips. We carted it up the dirt road to the non-denominational chapel in a rusty old pickup truck, the only motor vehicle on the island. We slept in the house of the superintendent of the island, who was also a lobsterman, so there was lobster meat in the scrambled eggs in the morning, and we were given the use of a motorboat so we could go to the mainland for restaurant dinners. We ate at the Tugboat Inn in Boothbay Harbor and Fisherman’s Wharf in East Boothbay, both of which are still there. Fisherman’s Wharf in 1976 is where I first heard Drop Kick Me Jesus Through the Goalposts of Life by Bobby Bare (Bill Clinton’s favorite country song according to Mr. Bare himself, as seen on a YouTube video) and I Just Kicked the Daylights Out of My CB Radio, composer unknown, sung by a raucous country band. That would have been less than two weeks after that triumphant concert at Symphony Hall in Boston. Who says I’m not well-rounded?

What an adventure it was for a twenty-year-old with stars in his eyes. I was asked to visit the organ ten years ago to update the assessed value of the organ for their insurance policy and rode out to the island on the same ferry, refreshing my memories of that wonderful adventure as a fledgling organbuilder.

The wind

In 1995, I restored an organ built by E. & G. G. Hook & Hastings (Opus 466, 1868) and relocated it to the Follen Community Church (UUA) in Lexington, Massachusetts. The project included the restoration of the feeder bellows so the organ could be pumped by hand. Yuko Hayashi brought her organ class from New England Conservatory to Follen several times to experience the difference between the sound of the organ when pumped by hand or fed with an electric blower.

When that project was finished, one of the first recitals was played by Peter Sykes, and unbelievably, there was a power failure midway through. Organ historian Barbara Owen volunteered to pump. As she walked up the steps to the platform, she faced the audience and recited verses from Oliver Wendell Holmes’s poem, The Organ Blower, excerpted here:

No priest that prays in gilded stole,
To save a rich man’s mortgaged soul;
No sister, fresh from holy vows,
So humbly stoops, so meekly bows;
His large obeisance puts to shame
The proudest genuflecting dame,
Whose Easter bonnet low descends
With all the grace devotion lends.

O brother with the supple spine,
How much we owe those bows of thine!
Without thine arm to lend the breeze,
How vain the finger on the keys!
Though all unmatched the player’s skill,
Those thousand throats were dumb and still:
Another’s art may shape the tone,
The breath that fills it is thine own. . . .

This many-diapasoned maze,
Through which the breath of being strays,
Whose music makes our earth divine,
Has work for mortal hands like mine.
My duty lies before me. Lo,
The lever there! Take hold and blow!
And He whose hand is on the keys
Will play the tune as He shall please.

Never was a memorized verse inserted so deftly. Judging from the graffiti we find around the pump handles of historic organs the reality is that pumping the organ was less lofty than what Mr. Holmes observed or imagined.

I have heard stories about how organists resisted the development of electric playing actions at first, claiming that being separated from their instruments by wires would make playing impersonal. They got over that quickly as the Skinner Organ Company, to name one, built its 301st organ in 1920. I have never heard any hint that organists resisted the introduction of electric organ blowers.

Marcel Dupre’s Recollections, published in translation by Ralph Kneeream, relates a story Dupré told of a Sunday morning at the Cathedral of Notre-Dame in Paris. His visitor in the organ loft was Claude Johnson, one the directors of Rolls-Royce. (Johnson had commissioned Dupré’s Fifteen Pieces, Vêpres du commun des fêtes de la Sainte Vierge, opus 18, which are dedicated to him.) Dupré was improvising on full organ after the Mass when the organ wind stopped. When Johnson asked what the trouble was, Dupré replied that the five men who were pumping the organ stopped when they got tired. Johnson went behind the organ, gave them some money, and Dupré started playing again, but not for long. When the wind died again, Johnson announced that he would give an electric organ blower to Notre-Dame and asked Dupré to have Cavaillé-Coll develop a plan, adding, “Since I am an Anglican, it would probably be wise to have the Cardinal’s approval.”1 Dupré wrote that this happened in 1919. I can only assume that he was correct, but that seems pretty late in history for such an important church to get its first electric blower.

Newfangled

In the nineteenth century, officers in the British Navy opposed the introduction of steam-powered vessels, complaining that the long tradition of sailors would be reduced to a mob of mechanics. They were overlooking the fact that a steam-powered vessel would be deadly to a sailing ship as it could operate against wind and tide or without wind at all. While commercial shipping converted quickly to internal combustion propulsion, sailboats have been popular as pleasure craft without interruption. Kingfisher has a twenty-horsepower diesel engine mounted in a spacious compartment under the deck of the cockpit that allows us to “sail” to and from docks and moorings, mostly without incident.

We bought Kingfisher from the boatyard near New Bedford, Massachusetts, where she was built. That first summer, we sailed her 250 miles home to Maine. We did not sail at night, so the trip took six days and five nights. Later, I wrote an essay about our maiden voyage for Catboat Journal, a quarterly magazine published by the Catboat Association. A guy in California, who would be teaching a class for sailing catboats the next summer at the Wooden Boat School in Brooklin, Maine (about seventy-five miles from home by water), emailed me suggesting that if we happened to be nearby at that time, he would love to have us address the class. The Wooden Boat School is a mecca for sailors, and we made sure we would just happen to be there, planning our summer’s cruise around this very event. It was a thrill to have our fiberglass boat on a guest mooring there.

Joining us as a casual commentator for the class was Bill Cheney, widely known in our area for his virtuoso sailing of a catboat, the same model and make as ours with one substantial difference—his boat has no engine. At dinner after the class with the students and their instructor, Bill and I were regaling the table with stories when I admitted that I am not the sailor he is because I am happy to have the engine for close maneuvering and for getting places when there is no wind. His response, “Where do you keep your wine?”

Notes

1. Marcel Dupré, Recollections, trans. and ed. Ralph Kneeream, Belwin-Mills, 1972, 69.

In the Wind: What Your Organ Service Technician Works With

John Bishop
Hot pot, glue pots, ultrasonic cleaner

String too short to save

After my freshman year at Oberlin Conservatory of Music, I spent the summer working with Bozeman-Gibson & Company in Lowell, Massachusetts. It was 1975, and on my first day working in an organ shop, I was set up in the parking lot with sawhorses, a set of painted façade pipes, a can of Zip-Strip®, and a hose. If that wasn’t enough to send me running, I guess I was hooked. They were working on the restoration of an 1848 Stevens organ in Belfast, Maine, completing a new organ in Castleton, Vermont, and installing a rebuilt historic tracker (I do not remember the builder) in a Salvation Army chapel in Providence, Rhode Island. A lot of the summer was spent driving around New England between those organs, my first glimpse into the life of a vagabond organ guy.

During my sophomore year I started working part time for John Leek, the organ and harpsichord technician for the Oberlin Conservatory of Music. I spent the next summer working with Bozeman during which the company moved to their permanent workshop in Deerfield, Massachusetts. There were a couple hours of “barn building” each day after the organ building. I continued part time with Leek as long as I was a student and switched to full time after I graduated. Counting the summers and part-time work, I have been at it for forty-six years.

After Christmas of 2019 I retired from working on organs on site and in my workshop. No more weeks spent wiring organs, no more service calls, no more console rebuilds—my favorite workshop job. I hasten to add that I continue to run the Organ Clearing House, managing the sale of vintage organs, and keeping the crew busy. I am still working as a consultant and still writing monthly columns. They will have to snatch the MacBook® from my cold dead hands. I have not yet imagined a time when I would not be doing some type of work with pipe organs.

With the outbreak of Covid, Wendy and I left New York City for our place in Maine, bringing the families of two of our kids with us. My private workshop, the three-car garage, became a staging space for groceries for our expanded household as we quarantined everything we brought into the house. When winter turned to spring, we added a refrigerator beside the garage freezer. The workshop has always been at least part boatyard. I have a couple shelves of boat parts, the expensive stainless-steel screws we use around salt water, and there are several lengths of surplus line hanging on a wall. You never know when you are going to need some more line. It is also a gardening shed and kitchen overflow storage for the bigger pots and pans. Lobster pots, roasting pans, and canning jars live on the shelves above the fridge.

This sounds like a lot of clutter, but I still have not mentioned the cabinets, shelves, and industrial drawers full of organ parts and hardware I have accumulated over the years. One year I restored an Aeolian residence organ with its paper roll player. It was playable in the shop for a summer, and we had a string of dinner parties during which we would suggest a break before dessert and leave the table for an organ demonstration. Some of Wendy’s publishing friends and colleagues needed that to understand just what I do for a living. “It was always mysterious to me!” I have rebuilt four or five consoles here, refinishing cabinets, rebushing keyboards, and retrofitting solid-state controls and electric drawknobs.

I know I will keep most of the general hardware as long as we live here. It is handy to have hundreds of sizes of screws arranged in drawers to support home repair projects. This summer, I cut up several lengths of half-inch threaded rod and collected the necessary washers, nuts, and lock washers for a tool hanger I built in the shed. Mending plates, corner braces, and hinges will always come in handy. I have felt and punches to make pads for the bottoms of chair legs; I have lubricants and finishes for pretty much any purpose and big, well-lit workbenches. It is my own private hardware store. Funny, I still go to the hardware store most weeks.

He polished up the handle of the big front door.

Along with his organ work, John Leek built harpsichords, and as we made those keyboards and brass levers to control “choirs” of jacks, I learned about polishing. I have a bench grinder that spins abrasive wheels, wire wheels, and cloth polishing wheels. There is a drawer full of bars of polishing compound, a rake for dressing the cloth wheels, and the nasty wheel with an iron handle for dressing the abrasive wheels. I rejuvenated a rusty cast-iron skillet using the wire wheel. Handy.

There is a case of Parson’s sudsy ammonia on a high shelf. I think there are ten bottles left in it. It is a terrific solution for use in my ultrasonic cleaner. I have used it to clean reed shallots and tongues, little brass console parts like screws and switches. I will hang onto all this because there are lots of things around the house that need polishing, and Wendy’s engagement ring looks great after an ultrasonic swim in sudsy ammonia.

Totally tubular

I have worked on all sorts of pneumatic actions from different organ builders, many of which incorporate some type of rigid or flexible tubing. Seventy-year-old rubber tubing is likely to be crumbling apart. Quarter-inch (interior diameter) tubing is common to many different types of organs, so I have hundreds of feet of that in a coil, destined to be cut into six-inch pieces. There is about forty feet of three-quarter-inch (ID) heavy plastic tubing with nylon webbing embedded. It is made for high-pressure hot water in small gasoline engines, and it was great for use as pneumatic tubing in a big expression motor. I have coils of copper tubing and some straight lengths of aluminum and brass tubing. You never know when you are going to need some.

Parts is parts.

Sometime ago I got the idea that it would be clever to have a supply of the waxed boxes used for Asian carry-out food for storing specific organ parts. I used them for a while, decided they were ridiculous, and discarded most of the minimum order of 1,000 boxes, but some are still around. One is labeled “Schlicker console parts.” I installed a Peterson system in a Schlicker console. Having serviced many Schlicker organs over the years, I know that the little pressed metal toggles in the “ka-chunk” combination actions can wear and break or simply fall out, and here were two or three hundred of them going to waste. I used four or five for a service call repair, and I still have the rest of them. Pretty sure I am not going to need them again.

I have boxes of Austin magnets, Austin note motors, Kimber Allen keyboard contacts, pedalboard contacts, Heuss nuts, leather nuts, compass springs (for the pallets in slider windchests), pouch springs, fiber discs (for making pouches and valves), many sizes and styles of felt and paper punchings for regulating keyboards, and even coils of wire for stringing harpsichords.

For a short while I repaired and rebuilt harmoniums, and I have a heavy box full of the brass reeds. They must have been salvaged from derelict instruments. I do not remember where I got them, but I doubt I did the salvaging because I would have kept them separated and labeled by voices. I may have used ten of them, and the rest are here if anyone wants them. A soak in sudsy ammonia would help. Another box is full of keyboard ivories. I “harvested” them from old pianos and organ keyboards, and having a miscellany of ivories really is useful as you can pick through them to match color and size. While I used many of them for service call repairs and refurbishing old keyboards, I am probably finished with them now.

On the high shelf near the tubing, there is a stack of boxes of various types of windchest magnets. Some have pipe valves that work either electrically or pneumatically, others are the standard “screw cap” chest magnets for pitman and offset chests. And for those times when you are changing wind pressure, there are boxes of magnet caps with one-quarter-inch and three-sixteenths-inch exhaust holes. None of these will have household use.

There are about twenty three-foot cardboard tubes in the rafters containing skins of leather and yards of felt, fabric, and cork. There is enough material to releather a ten-stop pitman chest and a half-dozen reservoirs. There is pouch leather, gusset leather, alum-tanned leather for reservoir belts, and several types and weights of pneumatic leather. I am not sure how much of it I will use, but as I recently gave Wendy a big piece of thin black felt for a sewing project, I will assume it is worth keeping. Since it is up high, it is not in anyone’s way.

Twenty or thirty years ago, industrial chemists developed spray cans of graphite lubricant, perfect for treating windchest tables, sliders, and toeboard bottoms so slider stop action would work smoothly. Before switching to that, I mixed flake graphite with denatured alcohol creating a paste that I scooped with latex-gloved hands and rubbed over all the surfaces. It was a messy process, but when the alcohol evaporated, a rich, even coat of graphite glistened on the wood. Heaven help you if you spilled any on the floor. I have most of a gallon can of graphite that I guess I do not need anymore. I also have half a case of that graphite spray. I can use it on snow shovels to keep snow from sticking to them.

Material handling

In industrial catalogues, material handling is the section that includes dollies, carts, pallet jacks, and all the tools and equipment used to move things around. You can buy a Drum Dolly, a two-wheeler designed specifically to handle 55-gallon drums or a refrigerator dolly—you can guess what that’s for. A refrigerator dolly is a two-wheeler with straps to hold the load in place, and rubber belts that move over wheels on the back so you can haul the fridge up stairs. I have used mine for hauling reservoirs upstairs to choir lofts. The upright freezer in the garage needs to be defrosted occasionally. That can be a nasty job, but it is pretty simple here, and we have been “eating it down” in preparation. Soon, I will move the last few things into the top of the Covid fridge, wheel the freezer through the overhead door, and stand it in the dooryard facing the sun with the door open. It takes a few hours, and there is no need to catch the water.

I have a come-along, a tool with a steel cable, hooks on both ends, and a long handle that pumps a ratchet. I bought it when we were installing an organ and realized it needed to be a few inches to the left. A half-dozen pumps of the handle was all it took to scootch the organ to its proper place. I have not used it on a job since, but we have a half-mile wooded driveway that trees fall on occasionally. I can often hitch a chain to loops on my car and drag a tree out of the way, but several times I have used the come-along tied to another tree to do the job when I cannot make the angle with the car. We also use it to pull the dock out of the water. I am keeping that.

The opposite of the come-along is a house jack that I have used often when releathering reservoirs. After the hinges are glued to the ribs, the pairs of ribs are glued to the body and top, and the belts are glued on all around, you have to open the thing fully before gluing on the gussets. You are stretching all the new material and glue, and it can be a heavy lift, especially on a large reservoir. I have done it with blocks and levers, but a hand-pumped hydraulic house jack is just the ticket. When our daughter wanted to convert a small shed into a pottery studio, our son-in-law and I jacked up the shed and repaired its structure. I will keep the jack.

Another tool I used when gluing reservoirs is the big double-boiler you see keeping soup warm in a cafeteria line. Having hot wet rags is essential when using hot glue, and I have a Sharpie mark on the front for the little volume knob, setting the temperature high enough to soften excess glue, but not so hot that I cannot put my hands in it. When I was gluing four or five reservoirs at once, the pot would be hot all day, and I would change the water every hour as it got dark with the glue. We like to give big parties, and a steaming pot of clam chowder would be just the thing for a chilly fall cookout, but I think this appliance has too many miles on it for use in food service. It is handy for soaking labels off jars.

My Rubbermaid® rolling table has ball-bearing casters and a load limit of 500 pounds. I know it can bear more than that. It is about the same height as my workbenches and the rear end of my Chevy Suburban, so I can wheel a windchest or reservoir from the back of the car to the workbench without lifting anything, and it is perfect for moving lumber between planer, table saw, and cut-off saw. I can also wheel groceries from the car to the Covid fridge, and I have even used it to wheel our eight-foot fiberglass dinghy to the car. Yes, you can put an eight-foot dinghy in a Suburban and close the door. I get fussy when other people in the family leave stuff on my rolling table because I like to keep it free for the next use. I’m keeping it.

One of our kids bought a couple big inflatable rubber swim toys. I especially like the Grandpa-sized pink inner tube with its five-foot dragon tail, lots of fun for swimming off the dock with our grandchildren, and it is convenient to have an air compressor with a big assortment of fittings. It saves fifteen minutes of huffing and puffing when you could be in the water. The fifty-foot air hose hangs on a steel column between garage bays, so it only takes a moment to set up to check the air of the tires on cars parked outside.

Perspective

There is almost no end to the list of tools, materials, supplies, and equipment in my garage workshop. I am still using most of the tools for projects around the house. This summer I built a neat set of drawers using quarter-sawn oak to match my library table desk. I am just starting a new “private drive” sign for the top of the road using birch lumber left over from a set of bookcases I made for Wendy’s office. I will use a pin-router to make the lettering. Wendy is a talented and productive weaver, and there is nothing like an organ builder as tech department for a house with two looms.

I hope this little tour is informative to organists who might not know much of what is behind the service technician who works on your organ or the organ company that built or rebuilt it. Mine is a light-duty shop, a delight for me to work in alone or with a colleague or two. It is especially nice in the summer with the overhead doors open. I keep thinking I will not do any more organ work there, but it is easy to imagine a time when our crew is working nearby and something needs to be releathered quickly. I might just bend the rule.

In the Wind: Take good care

John Bishop
Gabler organ

One size fits all.

As a plus-sized organ guy whose shoulders are four or five inches wider than an airplane seat, I always sit in an aisle seat so I do not have to crunch up against my neighbor. Instead, I am regularly clobbered by the flight attendant’s cart and the sloppiest of my fellow passengers as they negotiate the trek to the restroom. Years ago, on a flight to who knows where, I was seated next to a young woman who was sitting with her legs curled under her on her seat. I marveled at her flexibility, and when we stood to deplane, I realized she was under five feet tall and weighed a hundred pounds or less. We had paid the same price for our seats, and she was sitting perfectly comfortably while I was squeezed into my seat like toothpaste in a tube. Hats, mittens, or leggings might be sold as one-size-fits-all, but I know that really means they will be loose on small people and tight on large people.

So it goes with education. Modern public schools are governed by the demands of standardized testing as if every child in America needs an identical education. My son Chris teaches English as a second language in an urban public high school where his students are first- or second-generation immigrants who speak Spanish, Vietnamese, and Chinese at home, as it is typical that their parents do not speak English. These kids cannot be expected to thrive if they are being held to the same standards as their classmates who grew up speaking nothing but English. It is a heinous form of discrimination.

My other son Mike did not finish high school but worked in a succession of bicycle shops as a teenager and graduated to specialized piping, building the complex networks of tubing in university research labs. When he told me he had learned to do internal welding on eighth-inch stainless steel tubing, I knew he was going to be okay. He has now had a fifteen-year career with an architectural fabrication firm where he builds high-end signage with complex electrical systems, like the miles of LED displays that encircle the guitar-shaped Hard Rock Hotel in Hollywood, Florida. He built and installed all the road signs for Terminal B of Logan Airport in Boston (“Central Parking, Next Left”), interior signs for Madison Square Garden including the jumbotron, and the new Whitney Museum of American Art in New York City. You might think that Mike is disadvantaged because he did not have algebra or calculus in high school, but he uses more complex mathematics at his workstation every day than many of us do in a lifetime.

I had an industrial arts class in middle school where I learned to use a stationary shear, a metal brake, rollers, and rivets making a half-pipe-shaped, sheet-metal firewood caddy with decorative black iron legs and hoop handle. That gold-painted beauty stood next to the fireplace in my parents’ home until they moved into assisted living forty years later. I had algebra in high school, but I sure spent a lot of days in my career as an organ builder developing the metal-working skills I learned when I was thirteen.

In his book Shop Class as Soulcraft (Penguin Press, 2009), Matthew Crawford wrote about the dwindling of public school industrial arts education as schools focused more on standardized testing and achieving 100% college admissions. The second paragraph of his book’s introduction begins, “The disappearance of tools from our common education is the first step toward a wider ignorance of the world of artifacts we inhabit.” He goes on to describe how modern engineering focuses on “hiding the works” by designing machines so that you cannot tell how they are put together or how they work. Open the hood of a new car, and you can hardly tell there is an engine in there, and to keep our precious hands clean, some newer Mercedes models do not have dipsticks, as if it is not the owner’s responsibility to pay attention to whether there is oil in the engine.

In 1917, Congress passed the Smith-Hughes Act that provided funding for manual training in public schools, both as part of general education and as designated vocational schools. Crawford cites that starting around 1980, 80% of public high school shop programs began to disappear.1 Throughout the book, he makes the case that while some people flourish practicing law or managing businesses, many people are cut out to work with their hands, gaining the satisfaction of making or repairing something, what he calls “primary work.” He points out that surgery is a meeting of intellectual and manual disciplines. Standardized testing implies that a kid who is destined to be a plumber needs the same foundation as one who will be a musician or a corporate executive. Who can tell the future of a ten-year-old? You can’t. You provide all children with an education that includes academics, the arts and humanities, the industrial world, and sports, and hope that each child will be captivated by something—liberal arts for teenagers.

Simply reading the table of contents of Crawford’s book gives an overview of his point of view regarding the manual arts: “A Brief Case for the Useful Arts;” “The Separation of Thinking from Doing;” “To Be Master of One’s Own Stuff;” “The Education of a Gearhead;” “The Further Education of a Gearhead: From Amateur to Professional;” “The Contradictions of the Cubicle;” “Thinking as Doing;” “Work, Leisure, and Full Engagement.” As an organ builder, I have spent much of my life negotiating and contemplating the differences between blue- and white-collar work, and I recommend this book as a good read with lively writing and philosophical musings from the life of a literary motorcycle mechanic.

Early in my career, living and working in Oberlin, Ohio, one of our friends taught diesel mechanics at the vocational high school. What could be more valuable to a rural farming community than a new generation of diesel mechanics? Let’s face it, we need plumbers and auto mechanics more than we need organ builders. Those kids at Voke-Tech were onto something.

Jack of all trades

David Margonelli was a woodworker whose shop was in Edgecomb, Maine, a few miles downriver from our house. His first woodworking project was a Barnegat Bay Sneakbox, a small shallow draft boat that could be sailed, rowed, poled, or sculled. He was interested in Shaker furniture early on, and over the years developed pieces that combined the Shaker tradition with elegant curves such as a chest of drawers with bowed front or a bow-legged dining table. He had an elaborate vacuum table set up in his shop, like that found in many organ building workshops used for gluing windchest tables to grids, that allowed him to use the pressure of the atmosphere to create his curved elements.

We have one of his tables in our apartment in New York. It is made of cherry with the signature bowed legs and a neat sliding mechanism to allow the addition of two leafs for larger dinners. It has been the host of countless wonderful dinners, and its graceful shape is a beautiful addition to our home. David was a gnarly old guy, very sure of himself, and proud of his designs and craftsmanship, and I loved visiting his shop as much as I love sharing meals at his table.

Camden, Maine, a coastal town an hour or so east from us, is home to a little shop that sells handmade leather goods where I bought a bag made of supple black leather that I use as a second briefcase. It is just the size of an iPad or letter-sized paper folded in half and has three zipper compartments with enough space for a phone/iPad charger, hand sanitizer, pens, a Moleskine notebook, and a bottle of water. It has a long, adjustable leather strap so I can carry it around my neck, and I take it to local meetings and on short trips when I know I am not going to need my MacBook. I never met the artisan who made it, but I appreciate the accurate cutting of the material, the careful hand stitching, and the thoughtful usefulness of the design.

Early in 2013, I was tuning a venerable Hutchings organ in Cambridge, Massachusetts, when a 127-year-old ladder collapsed under me. I had a classic view of a receding ceiling and landed flat on my back on the miraculously flat and uncluttered floor of the organ. (If I had landed on a windline, I would have never walked again.) Following surgery and rehab, and our first season with our new sailboat (we called it the Sciatica Cruise), I contacted those clients whose organs were particularly treacherous and suggested (required) that we would install new ladders, handholds, and railings to reduce the risk of accidents. There is a little metal fabricating shop in our neighboring village of Damariscotta, Maine, where two guys cut and weld iron to make things like gear for commercial fishing boats amidst a gallery of tool calendars. I took them drawings for a collection of railings and ladders, and it is a lot safer to work in those organs now.

All these skills and the specialized tools involved are part of the art of organ building. Add to them sophisticated electrical systems, mechanical and structural engineering, architecture, and the musical realm of voicing and tuning, and you approach the complete organ builder.

It takes a village.

Having spent countless hours and days on job sites, bringing organs in and out of churches and maintaining those in place, I reflect frequently on the wide range of trades and vocations. An organ builder must be conversant with musicians, clergy, and the lay or professional leaders who operate churches and equally at home with custodians, electricians, HVAC workers, and the plumbers who install overhead sprinkler systems. We deal with building and fire inspectors, insurance adjusters, and lumber vendors. And working with the Organ Clearing House, almost every job involves scaffolding and trucking. It is funny to deal with a big-city pastor and a scaffold delivery driver from Queens, New York, in the same morning, especially when it turns out that the pastor is the tough customer while the driver is a sweetheart who just wants to get things right.

In 2004, we dismantled a huge M. P. Möller organ in a chamber above the 125-foot-high ceiling of a 19,000-seat convention center. As it was in the union city of Philadelphia, we started the project with a meeting that would define who would be allowed to do what work. Representatives of the unions for riggers, laborers, and carpenters were present along with administrators of the University of Pennsylvania, which owned the site. I described how delicate organ parts can be in spite of their industrial appearance, and the guy from the riggers’ union assured me that their men had vast experience. “We’ve been rigging in Philadelphia for 100 years, we’re the guys who moved the Liberty Bell.” I quipped, “Are you the ones who cracked it?” He did not think it was funny, but there were audible snickers around the table. The laborers insisted they should be in the organ chamber with us, moving the crates around. In the end, I won the point that we “owned” the organ chamber, that no one but us could handle organ parts until they were packed, but as soon as a crate or organ part got to the riggers’ rope we could not touch it again. We found out that “touch” really meant touch. Later in the job, one of our guys was on the floor guiding the laborers about how to place and stack crates, and he pushed a loaded dolly a few feet. A whistle blew, the work stopped, and I had to go to an emergency meeting with the unions to smooth things over.

Mike, one of the riggers, showed up one morning looking pretty rough. His pal told us that he had been in a bar the night before that had a boxing ring set up where patrons could wrestle with a bear, and the bear had won. Hughie (six foot, eight inches tall) stands out in my memory. The union was requiring him to attend anger management classes because he had beat up a highway toll collector as he passed through the booth. (Who gets that angry in that short a time?) We got along famously, and I will never forget the goodbye hug he gave me when the job was finished. The music theory classes I had at Oberlin had nothing to do with preparing me for Hughie’s hug, but I am sure that my knowledge of theory and harmony has informed my tuning.

§

We are all aware of the decline of “electives” in public schools like home economics, industrial arts, and the arts in general. The focus on college acceptance and standardized tests seems to hinder a thorough education. It is a common sentiment now that public schools could and should offer courses in life skills like family budgeting, tax preparation, investing, and auto maintenance, things that all of us need to know and learn on our own later if our parents do not teach us.

I repeat the quote from Matthew Crawford’s book, “The disappearance of tools from our common education is the first step toward a wider ignorance of the world of artifacts we inhabit.” When I visit an art museum, I marvel at the manual skills of painters, sculptors, potters, and jewelers from centuries and millennia past. If you have never held tools in your hands, never tried to carve a piece of wood, or never put brush and paint to canvas, you will have less understanding of the magic that is around you. Visit the ancient sites in Greece or Rome, and imagine the knowledge, skill, and singular sense of purpose necessary to build the Colosseum, a 10,000-seat amphitheater, or craft an ornately decorated pottery urn.

When I was an apprentice in John Leek’s shop in Oberlin, Ohio, he taught me how to plane a rough board by hand before letting me loose on the thickness planer. That was a great lesson about sharpening and handling tools and understanding the flow of grain in a piece of wood so my plane would not tear chips out of the surface if I worked against the grain. That experience enhanced my appreciation of the historic organs I have visited and worked on in the United States and Europe. That iconic fifty-foot-tall organ case in Haarlem is made of lumber that was planed and cut without electric tools and machines. I get blisters on my hands just thinking about it. Since the fire at the Cathedral of Notre Dame in Paris, France, we have seen video footage of the wooden superstructure of that building, made by artisans in the twelfth and thirteenth centuries. Felling trees, milling them into huge beams, transporting them from the forest to the city, and hoisting them hundreds of feet in the air with only the power of humans and oxen to haul wagons and turn winches is practically beyond belief.

Wendy and I are in New York City this week, and because of some complicated twists of schedule, a friend is staying in our house in Maine taking care of Farley, the Goldendoodle. She called at five o’clock Saturday evening saying there was no running water in the house. I walked her through resetting the pump at the wellhead without results, so I called Darren, the plumber. Meanwhile, I told her that she had three flushes (there are three toilets), after which she could use the outhouse. Darren was at the house in fifteen minutes, cleaned the filter at the pressure tanks (of course, the filter), and Cassie had water again. Take good care of your plumber, pay his bills promptly, and he will take good care of you.

 

Notes

1. Michael B. Crawford. Shop Class as Soulcraft (Penguin Press, 2009), p. 11.

In the Wind . . .

John Bishop
Taylor & Boody workshop (photo courtesy Taylor & Boody Organbuilders)

Pipes, wind, and wood

During the 1960s and 1970s, a number of organ building firms were founded, dedicated to building mechanical-action pipe organs according to ancient principles. This proliferation has been generally called the “Tracker Revival,” among other names, but more to the point, it was a renaissance of the philosophy of building pipe organs in small workshops rather than in large factories. In the years leading up to World War II, the larger American organ building firms adopted mass-production practices and controlled expenses diligently, which diminished the artistic and musical content of the instruments.

The idea of building pipe organs by hand was revolutionary, and there was a steep learning curve for these artisans. Early in the twentieth century, most American organs used relatively high wind pressure. Four inches on a water column was common, and firms like the Skinner Organ Company routinely used pressures from four to six inches on the Great, six to eight on the Swell, and often included Solo Tubas on ten, twelve, and even twenty-five inches. Such high pressures in large organs were only made possible by the invention of the electric blower that could produce huge volumes of pressurized air. Historic European organs typically used pressures of three inches or less (remember that before about 1900 pipe organs were blown by human power), and twentieth-century American builders, starting more or less from scratch, had to learn anew how to make large organ pipes speak beautifully on low wind pressure.

A critical part of measuring wind pressure is volume. The output capability of an organ blower is measured in cubic feet per minute at a given pressure. And in a mechanical-action organ with slider windchests, the delivery of pressurized air from the blower depends on the dimensions of the windlines from blower to reservoir to windchests, of windchest tone channels, of pallet (valve) openings, toe holes sizes in both windchests and pipes, and many other minutia. Several years ago, I visited the huge Beckerath organ at the Oratory of Saint Joseph in Montreal while the people of Juget-Sinclair were at work on the renovation and was amazed to see that small paper tubing was used to provide wind for the behemoth 32′ façade pipes, demonstrating that in the 1950s, venerable European firms were also busy learning how to do great things with low wind pressure.

E. Power Biggs released his influential two-record set, The Golden Age of the Organ, featuring the organs of Arp Schnitger and the chorale preludes of Ernst Pepping in 1968. That recording was a bellwether, as important as any single document in the inception of the new age of organ building. I wore holes in those LPs as a teenager, poring over the published specifications, gobbling up Pepping’s cheerful leaping music, and forming a lifelong relationship with Bach’s transcription of Vivaldi’s Concerto in D Minor. The gorgeous tones of the 8′ Principal in the Pedal with intertwining 4′ stops playing the violin are fully in my ears as I write.

John Brombaugh established his company in 1968 in Middletown, Ohio, and gathered a group of five partners that included John Boody and George Taylor. In the following years, an absolute who’s who of the twentieth-century pipe organ worked in Brombaugh’s shop, including many who went on to form their own companies. Brombaugh was one of the first to dig hard into the study of older organs in Europe, taking thousands of measurements, trying to learn what made those instruments sound so wonderful, and bringing that information back to the workshop to convert the numbers into music.

Ten years after starting the company in Ohio, when Brombaugh was eager to move the company to Oregon, George Taylor and John Boody chose to stay and form their own company in Middletown. As part of the dissolution of the partnership, Brombaugh passed on to them a contract for a new organ of two manuals and eighteen stops for the Presbyterian Church of Coshocton, Ohio. George and John set up shop in John’s garage to build the organ. It was completed in 1979, and Harald Vogel played the dedicatory recital.

As they were finishing the organ in Coshocton, they dreamed of purchasing a school building, thinking that with high ceilings, big windows, and wood floors, such a building would make a great workshop. George’s sister was graduating from Mary Baldwin College in Staunton, Virginia. George and John drove down to attend, and a college friend of George’s suggested an old school in town that was available. During a short visit, they immediately started talking about the price and bought the building for $11,000. More than forty years later, Taylor & Boody is still building organs there.

§

John Boody and I have shared a special bond as I maintained the E. & G. G. Hook & Hastings organ (Opus 635, 1872) in the First Baptist Church in Wakefield, Massachusetts, where John grew up and where his grandfather had been pastor. (Sadly, the church and organ were destroyed by fire on October 24, 2018.) We have been friends for a long time and have shared many a meal, wiling away convivial hours, and we have collaborated a few times. I spent a cheerful ninety minutes on the phone with John on January 10, 2021, hearing his thoughts about the history of Taylor & Boody.

John expressed gratitude for the opportunities he and George had to study European organs. He talked especially about their encounter with the 1702 Schnitger organ in the Aa-Kirk in Groningen, the Netherlands, where with Lynn Edwards and Cor Edeskes they had the privilege of removing the pipes from the iconic organ for exact measuring. They measured the windlines and other components of the wind system, measured critical dimensions of the windchests, and analyzed the structure of the organ. John spoke with reverence about blowing on those ancient pipes and how the experience defined the future of their work. “That really set the pace for us. That was before we plugged in a machine.” 

After that first organ in Coshocton, Ohio, several modest contracts came their way. Arthur Carkeek, professor of organ at DePauw University, Greencastle, Indiana, advocated Taylor & Boody to build a twenty-two-stop organ for the First Christian Church in Vincennes, Indiana (Opus 4, 1981). There followed a twenty-stop organ in Cincinnati, twenty-four stops for Richmond, Virginia, and a couple of one-manual organs, before they got to Opus 9 (1985), a four-manual organ with fifty-two stops for Saint Joseph’s Chapel at the College of the Holy Cross in Worcester, Massachusetts.

Late in our conversation, I asked John how he would define the work of Taylor & Boody. “It’s that sound we made at Holy Cross where we had all those lead pipes working together. We never built a squeaky organ like other people thought Baroque organs should be; our organs have that dark, chocolate, choral sound, the core of the organ was different. I think that really grabbed people’s attention, and that has worn well. And Grace Church, New York, still has that, and Saint Thomas Church Fifth Avenue. So that has stuck with us. And I think that, for me, that’s what makes an organ an organ. It’s that Principal, choral sound.” Their first few organs were built with the memories of that Schnitger organ fresh in their minds, and the opportunity to build the large organ at Holy Cross established the identity of their work.

John and I talked generally about the work of some of our colleagues, and I made the comment, “there’s a group among us who tip their hat to Mr. Skinner every time they get out of bed.” 

Boody: “That’s good, and that’s bad. I would say we have to move ahead.” 

Bishop: “Somebody listening to what John Boody just said would answer, haven’t you been looking 300 years back ever since you first had a chisel in your hand?”

Boody: “No, exactly the opposite. We were looking to the future. We wanted to build organs that stand tall into the future, that people would love on their own merits.”

Bishop: “So how do you translate the influence of Niehoff and Schnitger into the future?”

Boody: “You have to go with the music. You have to think of all the mechanical parts and other components you make in the shop as a conduit to making music. And you have to think about how all those parts work together. We focused on the music.”

The means of Grace

The Taylor & Boody organ at Grace Church in New York (Opus 65, 2013) was both a departure and continuation in the history of their work. Wendy and I live at Broadway and East 9th Street in Manhattan (Greenwich Village), Grace Church is at Broadway and East 10th. While the organ installation was underway, I shared some grand evenings with John and his co-workers, both in neighborhood restaurants and in our apartment. They were working on a complex instrument (tracker action in three separate cases with a remote console, and an “action tunnel” under the floor of the chancel), and those evenings were bright and fun.

That landmark organ with four manuals and seventy-six stops combines the Schnitger heritage of those marvelous “choral” choruses of lead Principals with the expressive range of the best Skinner organs. Acoustic scientist Dana Kirkegaard stipulated the construction of the expression boxes: two-inch-thick poplar lined on both sides with three-quarter-inch plywood, making a massive and dense enclosure, and shutters everywhere, even on the back of the box, shutters with an unusual range of motion, the whole providing an astonishing expressive effect. All that, plus a sophisticated solid-state combination action, sensitive mechanical action, and a few solo voices on really high pressure, combine to make an exciting instrument capable of countless effects. But wait, there’s more! Standing in the rear gallery, more than a hundred feet from the organ, are the lowest twelve notes of the 32′ Open Wood Diapason, all that remains of Skinner Organ Company Opus 707, built for Grace Church in 1928. Those twelve pipes were restored with a discreet wind supply and wired as an extension to the new 16′ Double Open Diapason of the Taylor & Boody organ, a fitting bottom to the grand new organ and testament to the musical history of the church.

Wind

As John Boody and I talked about the Grace Church organ, he spoke especially of the wind system. Superficially, we think of the pipe organ as a keyboard instrument. In fact, it is a wind instrument operated by keyboards. The organ at Grace Church has more than a dozen 16′ stops and twenty 8′ flue stops. Making an organ like that go is all about moving wind. John spoke proudly of the fellow in their shop primarily responsible for the wind system with large capacity wood wind ducts with curves for turns rather than right angles, those gentle turns moving the wind in different directions without creating eddies that can disturb the speech of the pipes. 

Multiple parallel-rise reservoirs ensure that there’s plenty of volume available to make those big sounds and that the wind is regulated effectively so there is no whiplash from a sudden shift from ffff to ppp. There is a lifetime of thought and experimentation in the wind system of each Taylor & Boody organ.

Pipes

There are a number of companies in the United States and Europe that make organ pipes to the specifications of the organ builders who order them. Pipe making is a complicated art that involves considerable specialized equipment for melting, blending, casting, planing, hammering, cutting, and soldering metal. It takes a lot of investment and effort for a small company to develop those abilities, but Taylor & Boody committed early to the idea that they should make their pipes. There is a room in their workshop with the cauldron for melting and mixing alloys and a ten-foot-long casting table. Molten metal is ladled and poured into a wood hod that runs on rails along the sides of the casting table. When the hod is full, two workers walk it swiftly down the table, leaving a thin pool of shiny molten metal. I have witnessed this process there, marveling at the moment a few seconds after the sheet is cast when the metal flashes over from liquid to solid.

When the sheet has cooled, it is rolled up like a carpet so it can be safely transported to the next steps in the process. John talked about the importance of the precision of making pipes. If a pipe is not neatly made, the voicer has to try to correct the pipe maker’s mistakes. John’s daughter-in-law B. J. Regi makes all the smaller pipes. John said, “she makes exquisite pipes. And you know, that’s the deal. If you go to start voicing an organ and everything’s lined up well, the mouths are beautiful, and the windways are pristine, you can make good sound right away.” Robbie Lawson heads the pipe shop, and B. J. helps him with the larger pipes. 

Wood

John Boody attended the forestry school at the University of Maine at Orono (he holds a Bachelor of Arts degree in vocal performance) and has loved and respected wood throughout his career. Taylor & Boody has a sawmill where they cut all the lumber used in their organs. After it is sawn into boards, the wood is dried in a kiln made from a retired refrigerated (and therefore insulated) semi-trailer. The lumber is stacked neatly in piles, separated by the organ. In 2009, Wendy and I visited Thomas Jefferson’s home at Monticello, and we spent a night with the Boodys. (We were treated to fresh eggs from John’s chickens for breakfast.) John showed us the huge oak logs from which the matching organ cases of the Grace Church organ would be made.

The sawmill provides the company with the most desirable wood, especially quarter-sawn white oak. Black walnut has beautiful grain patterns and rich color. It is very expensive to purchase from a hardwood supplier, and it is typically used only for decorative casework and furniture. But since walnut trees are plentiful in their area and they are messy to have in your yard, neighbors often cut down walnut trees and offer the logs to the T&B sawmill. This allows them to use the stable and beautiful wood to make action parts and wood organ pipes. Carefully milled, beautiful lumber is a hallmark of Taylor & Boody organs.

John’s affinity with wood is so widely respected that he has recently started writing a regular column for the journal of the International Society of Organbuilders called “The Wood Guy,” in which he answers colleagues’ specific questions and writes about the wonders of wood, that most natural of materials.

And the hope of glory

Eighty organs in forty years. Some are small continuo organs. Some are larger one-manual organs. Many are two-manual organs with twenty or thirty stops. There are a bunch with three manuals, and a couple of four-manual doozies. As the company produced all those organs, they also produced a clan. John has retired from the workshop, though he still runs the sawmill, the “light-duty” job for the older guy, and George is preparing to retire. John’s son Erik is running the company, and his daughter-in-law B. J. and son-in-law Aaron Reichert are both part of the workshop.

John is a prolific gardener. Looking at his Facebook page during the summer, you might think they were going to make zucchinis into organs. There is a swirl of grandchildren about. I recently saw a photo of a wee lass pushing a broom in the sawmill. It’s been a lifetime since those twenty-something partners were digging into that Schnitger organ in Groningen, understanding what the old master had to offer, and converting that experience into a creative career.

Halfway through our conversation, the name of a mutual friend and colleague came up, and John’s gregarious personality shone through. “He’s a dear man. And you think of our whole trade, we have great people. I love to go to APOBA meetings, I love to go to the AIO. Right down to the little one-man-shop guys, there are some great people out there.” John Boody and George Taylor have been faithful members of that band of great people. Their organs have influenced countless musicians around the world, and they reflect and amplify the harmonies of the workplace they founded in the schoolhouse on the hill.

Photo caption: Taylor & Boody workshop, Christmas 2020 (photo courtesy Taylor & Boody Organbuilders)

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