In the Wind: large pipe organ blowers

How does it work?

It happened again. I sat at this desk for days mud wrestling with an unruly topic for this column. Twice I had more than a thousand tortured words on the screen, went upstairs for a break, and came back to Ctrl-Shift-A-Delete. But Anthony Tommasini, music critic for The New York Times, came to my rescue with his article under the headline, “Why Do Pianists Know So Little About Pianos?,” published November 12, 2020. This article was born as the outbreak of COVID-19 got rolling in New York City last March and his piano needed tuning, but his apartment building was locked down and workers from outside were not allowed in except for emergencies. “An out-of-tune piano hardly seemed an emergency.”

He quotes the brilliant Jeremy Denk as not knowing “the first thing about piano technology.” Denk, whose playing I admire deeply and who like me is an alumnus of Oberlin College, had the same issue as Tommasini when his building locked down, but convinced the superintendent of his apartment building that because playing the piano is his profession, his tuner should be accepted as an essential worker. It worked.

Tommasini singles out Mitsuko Uchida as one prominent pianist who is an intimate student of piano technology. He quotes her as saying, “you get stuck when the weight is different key to key, the piano has been sloppily prepared, and the dampers have not been adjusted—or the spring in the pedal.” She went on, finding trouble when “the pin underneath the key [guide pin] is dirty, or the other pin in the middle of the mechanism [balance pin] is dirty, rubbing, or slurping.” I love the word slurping in this context.

Tommasini reminds us that orchestral players know more about their instruments than most pianists, and that unlike pianists, orchestral players own their instruments and can carry them with them between performances. Vladimir Horowitz traveled with his own piano, but then, Horowitz was Horowitz. You tell him “No.” Unusual among modern pianists, Mitsuko Uchida travels with her own piano. When Tommasini asked her if the institutions where she plays cover that cost, she said “usually not.” But she went on, “I have no excess otherwise. I don’t need country houses, expensive jewelry, expensive cars, special collections of whatever.” I suppose her usual fees cover that cost and still provide her with lunch money.

Tommasini concluded the column: Back at my apartment, the technician finally dropped by, tuned my piano, and made mechanical tweaks to a few of the keys. Afterward, it felt and sounded vastly better. I have no idea what was involved.

Press the key and the pipe blows.

The pipe organ is the most complex of all musical instruments. It is such a sophisticated machine that other musicians, including some world-renowned orchestral conductors, consider it to be unmusical. While a violinist or clarinetist can accent a note by applying a touch more energy, what a single organ pipe can do is all it can do. The organist can accent a note by tweaking the rhythm—a nano-second of delay can translate into an accent—or by operating a machine. A twitch of the ankle on the Swell pedal does it, so does coupling a registration to another keyboard with a soft stop so a note or two can be accented by darting to the other keyboard. The creative organist has a bag of tricks that bypass the mechanics and allow the behemoth to sing.

I have been building, restoring, repairing, servicing, selling, and relocating pipe organs for over forty-five years, and I know that many organists have little idea of how an organ works, so I thought I would offer a short primer. If you already know some or most of this, maybe you can share it with people in your church to help them understand the complexity. In that case, it might help people, especially those on the organ committee, understand why it is so expensive to build, repair, and maintain an organ.

Pipes and registrations

A single organ pipe produces a tone when pressurized air is blown into its toehole. The construction of the pipe is such that the puff of air, which lasts as long as the key is held, is converted to a flat “sheet” that passes across the opening that is the mouth of the pipe. The tone is generated when the sheet is split by the upper lip of the mouth. This is how tone is produced by a recorder, an orchestral flute, or a police whistle. Organ pipes that work this way are called “flue pipes,” and there are no moving parts involved in tone production. Reed pipes (trumpets, oboes, clarinets, tubas, etc.) have a brass tongue that vibrates when air enters the toehole: that vibration is the source of the tone.

Since each pipe can produce only one pitch, you need a set of pipes. We call them ranks of pipes, with one pipe for each note on the keyboard to make a single organ voice. Additional stops are made with additional ranks. There are sixty-one notes on a standard organ keyboard. If the organ has ten stops, there are 610 pipes. Pedal stops usually have thirty-two pipes.

The Arabic numbers on stop knobs or tablets refer to the pitch at which a stop speaks. 8′ indicates unison pitch because the pipe for the lowest note of the keyboard must be eight feet long. 4′ indicates a stop that speaks an octave higher, 2′ is two octaves higher, 16′ is an octave lower. Some stops, such as mixtures, have more than one rank. The number of ranks is usually indicated with a Roman numeral on the stop knob or tablet. A four-rank mixture has four pipes for each note. The organist combines stops of different pitches and different tone colors to form a registration, the term we use to describe a group of stops chosen for a particular piece of music or verse of a hymn.

The length of an organ pipe determines its pitch. On a usual 8′ stop like an Open Diapason, the pipe for low CC is eight feet long, the pipe for tenor c° is four feet, for middle c′ is two feet, and the highest c′′′′ is about three inches. Every organ pipe is equipped with a way to make tiny changes in length. Tuning an organ involves making those tiny adjustments to hundreds or thousands of pipes.

Many organs have combination actions that allow an organist to preset a certain registration and recall it when wanted by pressing a little button between the keyboards (piston) or a larger button near the pedalboard to be operated by the feet (toestud).

Wind

When playing a piece of music on an organ, the little puff of air through each organ pipe to create sound is multiplied by the number of notes and the number of stops being used. Play the Doxology, thirty-two four-note chords, on one stop and there will be 128 puffs of air blowing into pipes. Add a single pedal stop to double the bass line and you will play 160 pipes. Play it on ten manual stops and two pedal stops, 1,384. A hundred manual stops (big organ) and ten pedal stops, 6,420, just to play the Doxology, a veritable gale.

Where does all that wind come from? Somewhere in the building there is an electric rotary blower. In smaller organs, the blower might be right inside the organ, in larger organs the blower is typically found in a soundproof room in the basement. The blower is running as long as the organ is turned on, so there needs to be a system to deal with the extra air when the organ is not being played, and to manage the different flow of air for small or large registrations. The wind output of the blower is connected to a unit that most of us refer to as a bellows. “Bellows” actually defines a device that produces a flow of air—think of a fireplace bellows. Before we had electric blowers, it was accurate to refer to the device as a bellows. When connected to a blower that produces the flow of air, the device has two functions, each of which implies a name. It stores pressurized air, so it can accurately be called a reservoir, and it regulates the flow and pressure of the air, so it can accurately be called a regulator. We use both terms interchangeably.

Between the reservoir/regulator and the blower output, there is a regulating valve. Sometimes it is a “curtain valve” with fabric on a roller that operates something like a window shade, and sometimes it is a wooden cone that seats on a big donut of felt and leather to form an air-tight seal. In either case, the valve is connected to the moving top of the reservoir/regulator. When the blower is running and the organ is not being played, the valve is closed so no air enters the reservoir. When the organist starts to play, air leaves the reservoir to blow the pipes, the top of the reservoir dips in response, the valve is pulled open a little, and air flows into the reservoir, replenishing all that is being used to make music by blowing pipes.

Weights or springs on the top of the reservoir regulate the pressure. The organ’s wind pressure is measured using a manometer. Picture a glass tube in the shape of a “U,” twelve inches tall with the legs of the “U” an inch apart. Fill it halfway with water, and the level of the water will be equal in both legs. With a rubber tube, apply the pressure of the organ’s wind, and the level of the water will go down on one side of the “U” and up on the other. Measure the difference and voilà, you have the wind pressure of the organ in inches or millimeters. It is common for the wind pressure to be three inches or so in a modest tracker-action organ. In a larger electro-pneumatic organ, the pressure on the Great might be four inches, six inches on the Swell, five inches in the Choir, with a big Trumpet or Tuba on twelve inches. The State Trumpet at the Cathedral of Saint John the Divine in New York City is on 100 inches. I used to carry a glass tube full of water into an organ, a risky maneuver. Now I have a digital manometer.

In a small organ, the blower typically feeds a single reservoir that regulates the flow and pressure and distributes the wind to the various windchests through wind conductors (pipes), sometimes called wind trunks. In larger organs, it is common to find a regulator in the basement with the blower, and big pipes that carry wind up to the organ where it distributes into various reservoirs, sometimes one for each keyboard or division. Very large organs have two, three, four, or more windchests for each keyboard division, each with its own reservoir. A large bass Pedal stop might have one reservoir for the lowest twelve notes and another for the rest of the stop. And speaking of big pedal stops, the toehole of the lowest note of something like a 16′ Double Open Wood Diapason can be over six inches in diameter. When that valve opens, a hurricane comes out.

Windchests

The organ’s pipes are mounted on windchests arranged in rows on two axes. All the pipes of one rank or stop are arranged in rows “the long way,” and each note of the keyboard is arranged in rows “the short way.” The keyboard action operates the notes of the windchests, and the stop action determines which sets of pipes are being used. Pull on one stop and play one note, and one pipe plays. Pull on five stops and play a four-note chord, and twenty pipes play. In a tracker-action organ or an electric-action organ with slider chests, the keyboard operates a row of large valves that fill a “note channel” when a note is played and a valve opens. The stops are selected by sliders connected to the stopknobs, which have holes identical to the layout of the holes the pipes are sitting in. When the stop is off, the holes do not line up. When the stop is on, they do, and the air can pass from the note channel into those pipes sitting above open sliders.

It is common in electro-pneumatic organs for there to be an individual valve under every pipe. There is an electric contact under every note on the keyboard, a simple switch that is “on” when the note is played. The current goes to the “primary action” (keyboard action) of the windchest. The stops are selected through various devices that engage or disengage the valves under each set of pipes. When a note is played with no stops drawn, the primary action operates, but no pipe valves open. The stopknobs or tablets have electric contacts similar to those in the keyboards. When a stop is turned on and a note is played, a valve opens, and a pipe speaks.

We refer to “releathering” an organ. We know that the total pipe count in an organ is calculated by the number of stops and number of notes. An organ of average size might have 1,800, 2,500, 3,000 pipes. Larger organs have 8,000 or 10,000 pipes, even over 25,000. The valves under the pipes are made of leather, as are the motors (often called pouches) that operate the valves. Releathering an organ involves dismantling it to remove all the internal actions, scraping off all the old leather, cutting new leather pieces, and gluing the motors and valves in place with exacting accuracy. The material is expensive, but it is the hundreds or thousands of hours of skilled labor that add up quickest.

It’s all about air.

We think of the pipe organ as a keyboard instrument, but that is not really accurate. A piano’s tone is generated by striking a string that is under tension and causing it to vibrate. That is a percussion instrument. The tone of the pipe organ is generated by air, either being split by the upper lip of the organ pipe or causing a reed tongue to vibrate. The organ is a wind instrument. When we play, we are operating machinery that supplies and regulates air, and that controls the valves that allow air to blow into the pipes. When I am playing, I like to think of all those valves flapping open and closed by the thousand. I like to think of those thousands of pipes at the ready and speaking forth when I call on them like a vast choir of Johnny-One-Notes. I like to think of a thousand pounds of wood shutters moving silently when I touch the Swell pedal. I believe my knowledge of how the organ works informs my playing.

A piano is more intimate than a pipe organ, though technically it is also played by remote control as a mechanical system connects the keys to the tone generation. I am not surprised, but I am curious why more pianists do not make a study of what happens inside the instrument when they strike a key. I believe it would inform their playing. A clarinetist certainly knows how his tone is generated, especially when his reed cuts his tongue.

I have always loved being inside an organ when the blower is turned on. You hear a distant stirring, then watch as the reservoirs fill, listen as the pressure builds to its full, and the organ transforms from a bewildering heap of arcane mechanical gear to a living, breathing entity. I have spent thousands of days inside hundreds of organs, and the thrill is still there. 

That’s about 1,800 words on how an organ works. My learned colleagues will no doubt think of a thousand things I left out. I was once engaged to write “Pipe Organs for Dummies” for a group of attorneys studying a complex insurance claim. It was over twenty-five pages and 15,000 words and was still just a brief overview. Reading this, you might not have caught up with Mitsuko Uchida, but you’re miles ahead of Jeremy Denk.

A postscript

In my column in the November 2020 issue of The Diapason (pages 8–9), I mentioned in passing that G. Donald Harrison, the legendary president and tonal director of Aeolian-Skinner, died of a heart attack in 1956 while watching the comedian-pianist Victor Borge on television. The other day, I received a phone message from James Colias, Borge’s longtime personal assistant and manager, wondering where I got the information. I have referred to that story several times and remembered generally that it was reported in Craig Whitney’s marvelous book, All the Stops, published in 2003 by Perseus Book Group. Before returning Colias’s call, I spoke with Craig, who referred me to page 119, and there it was.

I returned Mr. Colias’s call and had a fun conversation. He told me that he had shared my story with Borge’s five children (now in their seventies). He also shared that when Victor Borge was born, his father was sixty-two-years-old, so when he was a young boy, he had lots of elderly relatives. His sense of humor was precocious, and when a family member was ailing, he was sent to cheer them up. Later in life, Borge said that they either got better or died laughing. I guess G. Donald Harrison died laughing.

Photo: Tracker keyboard action under a four-manual console, 1750 Gabler organ, Weingarten, Germany. (photo credit: John Bishop)

“It went zip when it moved and pop when it stopped. . . .”

In 1962 American songwriter and folksinger Tom Paxton wrote and recorded “The Marvelous Toy,” a nonsensical song with the catchy refrain that continued, “And ‘whirr’ when it stood still. I never knew just what it was, and I guess I never will.” As I was working out this essay in my mind’s ear, the song popped into my head, and I quickly found a raft of YouTube video performances including Tom Paxton himself singing with his grandson Sean Silvia, and the ubiquitous cover recording by Peter, Paul, and Mary released in 1969. The more you know about a machine, the easier it is to care for.

My colleague Amory and I were on the highway together—I was at the wheel, and Amory was half asleep in a highway-induced reverie when we passed a large truck whose trailer was a huge complex dedicated machine. Amory wondered half to himself, “What kind of machine are you?” I have always been fascinated by machines, what they do, how they work, and how to care for them.

I had a learning moment as a teenager mowing the lawn when the grass chute clogged. I stopped the engine, turned the mower over, cleared the clog, set it right side up, started it up, and continued mowing—for about thirty feet, when the three-and-a-half horsepower Briggs & Stratton engine stopped with a bang. While the mower was upside down, the motor oil ran out, and the engine ran about twelve seconds before it welded itself solid. It was like the proverbial customer in the auto parts store asking for a longer dipstick: “Mine doesn’t reach the oil anymore.” The other day, as Wendy and I were leaving our house in Maine to be gone for more than three weeks, I checked the oil in the backup generator and topped it off.

You are going to leave a parking space. You start your car’s engine, check the mirrors and back-up screen, put the transmission in reverse, and start the car moving backwards, steering so you wind up parallel with the curb. While you are still moving backward, you drop it into drive, the car gives a thud, and you start moving forward. At least that is what you do if you have no idea how the transmission (whether manual or automatic), universal joints, differential, crankshaft, and piston rods work. By changing the direction of your travel while the car is in motion, you have put excessive torque on all those critical parts and diminished the working life of your car’s drivetrain unnecessarily.

Try this: put the car in reverse, back out of the spot turning parallel to the curb, come to a complete stop as you move the gear shift to neutral, then shift into drive and start moving forward. No thud, no thump, no excessive torque, and you go merrily on your way.

Speaking of motor oil, I believe it is smart to let the engine run for thirty or forty seconds before you put the car in gear. When the engine is not running, all the oil is sitting in the oil pan at the bottom of the engine. When you start it, the oil pump pumps the oil to the top of the engine where the critical cams are opening and closing the intake and exhaust valves of the cylinders. If you put a load on the engine by moving the car before the oil is distributed throughout, you are adding unnecessary wear. Take a nice breath before you start rolling, and your camshaft will thank you. Have you ever noticed a light clattering sound just after starting the engine on a cold morning that goes away after a few seconds? That is the camshaft moving those valves, waiting for the oil to find its way to the top of the engine. I drive about 35,000 miles a year, and I have run six cars past 175,000 miles, three of those past 250,000.

After my parents retired to their home on Cape Cod, my tween-ish sons discovered that when you turned the faucets of the first-floor bathroom sink on, then off abruptly, you would get a loud clatter from the pipes within the walls. (I guess the plumber ran out of pipe clamps.) I told them how the rattling could lead to leaking joints hidden in the walls, but my mechanical wisdom fell on deaf ears. My older son Michael is as interested in all things mechanical as I am, and he grew into a career as a fabricator with superior welding skills and a vast knowledge of fasteners and connectors. He once described a project that required interior welding in eighth-inch stainless steel tubing. He reminisced about the banging of his grandparents’ plumbing, “We really were jerks, weren’t we?”

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Like millions of American children starting in 1969, my sons grew up watching Sesame Street, which included feature segments about how things are made. I remember a montage of scenes from a Crayola factory showing how crayons are made, but the real standout was filmed at the Teddie Peanut Butter factory in Everett, Massachusetts, and featured the 1920s-flapper-style song by Joe Raposo, It Takes a Lot of Little Nuts to Make a Jar of Peanut Butter. The video flips from one machine to another as peanuts are roasted, ground, “a little salt, a little sugar makes the goo taste really good and keeps it pumping through the pipeline like a peanut-butter-pumper should.”

How do they shell those billions of nuts for peanut butter, or those big jars of shelled pecans, walnuts, or heaven help us, Brazil nuts. It is a small triumph to free a Brazil nut or pecan with a standard-issue nutcracker without chipping or breaking it. Jasper Sanfilippo (1931–2020) worked in his father’s nut business from the age of nine until 1963 when his father passed away. Jasper had a degree in mechanical engineering, and he developed high-volume machines for shelling all varieties of nuts. His company acquired the Fisher nut brand in 1995, which quickly became the best-selling brand of shelled nuts in the United States. You can still see his name on the back of any Fisher nut package.

His nut fortune allowed him to pursue his passion for machines, especially automatic musical instruments along with steam engines and locomotives, gramophones, carousels, slot machines, and penny arcades. His grand house in Barrington Hills, Illinois, Place de la Musique, is still operated as a museum that is used for charitable events and, predictably, conventions of various organizations devoted to the pipe organ. There is an immense Wurlitzer theatre organ at the heart of the collection. I was particularly fascinated by the machines that played four violins simultaneously. The violins are mounted upside down and arranged like a compass—north, east, south, west—and a circular bow surrounds and plays all four instruments at once. There are dainty metal padded fingers to damp the strings along the necks, little mechanical marvels adjusted by fractions of millimeters for correct tuning of every note.

Console etiquette

If you are an organist for a church or university, you are likely to be responsible for the care of the organ, a complex and sophisticated machine that is subject to mechanical failures and sensitive to climate changes. If you know a little about how it works, you can protect it from unnecessary wear and tear, just like sparing the drivetrain in your car by not changing direction abruptly.

Years ago, I maintained a simple little organ in Lexington, Massachusetts, that was notorious for dead notes in the pedalboard. The organist was an elderly woman with luxurious long, thick gray hair who kept a hairbrush at the console, and part of our routine was to pull out the pedalboard and sweep up the great clumps of hair that were interfering with the contacts. We called it the hairball organ.

Do not wear street shoes when you are playing the organ. Gritty bits of sand and debris will wreck the hard finish on the pedal keys and gather as abrasives on contacts, felt bushings, springs, and guides. You might be tracking water, snow, or heaven help us, salt. If you have ever left salt in a silver salt cellar, you know how salt corrodes silver. If your pedalboard is less than thirty years old or has been rebuilt in that time frame, your pedal contacts are likely made of silver. Salt from your street shoes means dead notes.

Organists have asked me many times whether it is okay to stand on a pedalboard. Don’t. There are some obvious variables. An antique pedalboard is likely to be more delicate than a modern one. Some builders are known for producing especially sturdy pedalboards. In my experience Casavant gets the prize. Theirs are frightfully heavy and very robust. I am a heavy guy, and I am certain I could stand safely on a Casavant pedalboard. But my weight or yours standing directly on the pedal keys is far more downward force that we generate by simply playing, so we would be crushing the felt down-stops (ultimately increasing the travel of the pedal keys) and pushing the contacts or tracker action past their normal “on” position (ultimately spoiling their adjustment). And should you fall through, you will cause terrible damage requiring expensive repair.

I once commented to an organist about the big coffee cup sitting on the stopjamb while he practiced: “If that ever fell into the keyboards . . . .” I got a huffy reply, but a few days later it was a contrite phone call. The cup was full, and the coffee was sugary. The organ was in a big, busy church, and we did not want to miss a Sunday, so I took the keyboards to my workshop one at a time, took them all apart, cleaned everything, and replaced several octaves of guide-pin bushings. That was the end of the coffee cup habit.

Our furry friends

My mentor John Leek was a first-generation Dutch immigrant who was friends with a gaggle of guys who worked for Flentrop. When I was working with John in the 1970s and 1980s, we did a lot of work for Flentrop, especially installing new organs. Hans Steketee, then president of Flentrop, came to John’s place for dinner and a shop visit, and John and I showed him a half-dozen reservoirs that we were releathering, telling him that we did a lot of that kind of work. “What do you do, put mice in the organs?” he asked. Have you known an organist who might leave half a donut on a napkin on the console keytable? Rodents like donuts. Please do not bring food to the console.

When I was a teenager, I practiced in a church in Yarmouth Port, Massachusetts, on an organ built by William H. Clark in the Swedenborgian Church. There was a terrible bang from inside the organ late at night that had me jumping out of my proverbial skin. The minister had set a Havahart trap inside the organ and caught his raccoon. I wonder how many nights that raccoon was lurking inside the organ while I rattled away at the keys. The tracker action for the Pedal Bourdon went across the floor. I imagine that would have been like the Caribbean dancers who jump between pairs of poles rhythmically moving back and forth while being held close to the ground. I hope my teenage playing was rhythmic enough.

Keep your eyes open for signs of rodents in your organ. A particular favorite lair for little mousies is in between the keyboards of your organ’s console. Searching for a rattling sound in the keyboards, I have found messy trails and stashes of acorns on the keyboard behind the nameboard, another chance to imagine a manic dance for a little critter as the organist practices a wicked toccata. (Once when returning to our house in Maine after a while away, we found a stash of acorns in a pillowcase on our bed, a cozy but temporary home for a furry family.) Keyboard mice add to their comforts by harvesting the felt from capped pipes and keyboard bushings to make little multi-colored nests.

During a service call in Osterville, Massachusetts, a pipe was not speaking because there was an acorn inside it. There were well-marked trails through the organ, across windchests and across the tops of capped pipes (many of which were stripped of their black felt), and a mouse had dropped his acorn into the pipe. He was not complacent about his loss, going down to the rackboard and gnawing at the mouth of the pipe trying to free his nut, without success.

Aeolus, keeper of the winds

One of the most important tasks in caring for a pipe organ is lubricating the blower and keeping the blower room clean. In many churches, the blower is a heavy, dark monster lurking in a murky or dusty basement lair that is likely to be full of spider webs and the assorted creatures that maintain and frequent them.

It is best to keep the blower room clean, and you may be inspired to bring in a shop-vac, but I recommend a protocol for cleaning a blower room that ensures the blower will not blast loosened dust into the delicate mechanisms of the organ. You should leave this to your organ technician:

• Turn off the power to the blower to ensure it cannot be started during the process. There is typically a heavy cutout switch on the wall next to the blower.

• Seal the air intake of the blower with plastic and tape.

• Clean all the surfaces of the room with a vacuum cleaner. Use a bucket and mop on the floor. Use a cleaning agent with damp rags on the blower and ducts. (I like Simple Green.)

• Let the room sit idle for at least twenty-four hours to allow dust to settle.

• Clean the room again.

• Let the room sit idle for at least another twenty-four hours.

• Remove the plastic and tape from the blower air intake, being sure that no free dust enters the blower.

You can now start the blower, being sure that no dust is blown into the organ.

And most important:

Be sure that the organ is properly insured. The church’s insurance policies may be overseen by a parish administrator or a volunteer member of the property committee. Investigate whether the organ is clearly named in the policy. Many churches have a fine arts policy that covers musical instruments, stained glass windows, communion silver, and any other artwork that may be present. It is usual for an insurance carrier to require an assessment from a neutral pipe organ expert, someone other than your usual organ technician. The assessment and coverage should specifically be for the organ’s replacement value. In the case of a total loss, the organ could be replaced. In the case of partial loss due to fire, flood, vandalism, or even rodents, the insurance adjuster will negotiate with organbuilders and advisers to determine an appropriate settlement based on the replacement value.

The officers, organists, and members of many churches are blissfully unaware of the status of insurance coverage, leaving their organs at risk. It is the responsibility of organists and organ technicians to raise this issue.

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When I was a kid, the television had rabbit-ear antennae, often festooned with tinfoil, and when the reception was poor (it was always poor), we would slap the side of the machine as if that would knock those delicate vacuum tubes into submission. I have watched organists jab hard at intermittent piston buttons and stop controls, thinking that would get them to work, when in fact that was the cause of the fault. All our machines are the product of human ingenuity as applied to the laws of physics. There is no such thing as a machine that works better when treated roughly. Be gentle with your machines, and they will serve you well.

Mechanical failure

This morning while doing errands with Wendy, I noticed a lug nut on the tarmac next to our parked car. The inside thread was stripped bare, even shiny and smooth, and while the outside should have had six corners and six sides, only three corners and two of the sides were intact while the rest was rounded. I put it in my pocket and worried it with my fingers as we completed our errands and placed it on my desk when I got home. I have been glancing at it and handling it, wondering how it got so badly deformed. Was it cross-threaded onto the lug so aggressively that the thread was compromised? Did it fall off a car parked there? If so, how many other lug nuts were in such bad shape? How did the outside of the nut get rounded? Did other lug nuts on the same wheel suffer the same damage? It’s bad when a wheel falls off.

Take care of your machines.

For most of us, our cars are the most complex and sophisticated machines we own, and there are some simple maintenance procedures we follow to ensure smooth operation. The fact is that failure to take these steps can lead to serious damage and mortal danger. We change the oil every few thousand miles. When the engine is not running, the oil sits in a reservoir at the bottom of the engine known as the oil pan. When you start the engine, the oil pump brings oil to the top where it splashes about the camshaft and valves, and trickles down across myriad parts to be recirculated. If the oil gets dirty, it does not lubricate as well. If the oil runs dry, the engine parts heat to the point of welding themselves together. I once hit a rock with a lawnmower that cracked the oil drain plug inside the mower deck. The oil ran out, and the engine seized with a bang.

Did you ever notice how your car’s engine clatters for a few seconds when you start it on a cold morning? That is because the oil is extra thick and takes a moment to get to the top of the engine. Are you one of those drivers who starts the engine and immediately puts the car in gear? It would be better to wait until the oil gets to the top of the engine and the clattering stops before you put a load on the engine.

You are backing out of a parking space. You check your mirrors, shift into reverse, and start the car moving. When you shift into drive you hear a clunk from under the floor. Each of those clunks means a little extra wear on the transmission with its hundreds of precise interior fluid channels. I back out of the space, shift into neutral as I stop the car, then shift into drive before I start moving again. No clunk. It is an extra step, but I think it means my transmission will last longer. It is as easy to develop that habit as putting only one space after a period.

When my sons were young, they were delighted to find that they could cause the plumbing to make banging noises in the walls when they turned a bathroom faucet on and off at my parents’ house. My older son is now an expert fabricator with high-end welding skills, and we laughed together recently over that memory. They could have done serious damage to the house by breaking soldered plumbing joints inside the walls.

The same son was a wild driver early on. He loved going fast, he loved having smoke coming off his tires, and he pushed a series of cars to early ends, adding to the huge expense of many speeding tickets, cancelled insurance policies, and suspended licenses. When he finally broke those habits, he observed that it is lot less expensive to drive more conservatively.

Try it again without making noise.

The pipe organ is a musical wonder, and no other musical instrument has such complicated mechanical systems. Our habits at the keyboard and our attitudes toward our instruments can have a significant effect on their reliability. I do not need to mention the organist who habitually placed a sugary cup of coffee on top of the console stopjamb. I chided him about the ugly rings on the lovely, shellacked surface and warned about spills. The spill happened late on a Saturday night, and I was able to get the organ working a little before Sunday services, but removing the keyboards, replacing felt bushings, cleaning contacts, and regluing several of the sharp keys cost many thousands of dollars.

I do not need to mention the organist who played on a nineteenth-century mechanical-action organ and caused heavy bangs in the stop action because of the force he used on the drawknobs. The travel of those sliders is regulated and limited by little steel pins drilled and driven into the windchest tables. There are slots in the sliders that ensure the correct amount of motion, and the pins also fit into holes in the bottom of the toeboards, assuring that they are in the correct position. Slam, bang, thud hundreds of times every time he played, and the stops gradually grew softer and out of tune. Those guide pins were being driven out of their holes, and the sliders were traveling too far, going past the “full open” position, constricting the holes, and underwinding the pipes. That one was a $45,000 repair, removing all the pipes, lifting the toeboards and sliders, repairing the holes, redrilling the pins, then putting everything back together and tuning the pipes.

And I do not need to mention the organist who complained that the piston buttons were unreliable, demonstrating them to me with furious jabs from a powerful finger. Maybe, just maybe, the tiny contacts and springs that make those buttons work were prematurely worn by that vigorous action.

Just as I try to avoid that extra clunk when shifting my car from reverse to drive, you might listen to your console as you play. Does your technique cause extra noise at the keyboards? You might be causing excessive wear.

When I was a student at Oberlin, I had an important lesson about unnecessary noise. My organ teacher, Haskell Thomson, organized a winter term project for a group of us to be led by Inda Howland, the legendary teacher of eurhythmics and disciple of Émile Jacques-Dalcroze. For three days a week through the month of January, ten or fifteen of us bounced balls and performed other rhythmic exercises to the beat of the drum that always hung on a lanyard around Ms. Howland’s neck. Later in the month, we moved to practice rooms where we played for each other with her coaching and comments. I was working on Bach’s Toccata in F at the time, and I bravely powered through those familiar pedal solos with my pals huddled around the little organ. (If you think the acoustics in a practice room are dry, add twelve inquisitive pairs of ears to the mix.) When I finished, Ms. Howland referred to the noise of my feet on the pedalboard, “try it again without making noise.” That one comment had more impact on me than ten years of organ lessons, and I know my pedal technique improved from that moment on.

The most mechanical of musical instruments

A violin is nothing more than a curiously shaped box with a neck and four strings. The only things mechanical about it are the tuning pegs that use “friction fit” to maintain the exact tension to keep each string in tune. A trumpet has three valves that function like pistons, connecting tubes of various lengths as their positions are changed. A clarinet has eleven holes that are opened and closed by a system of levers operated by the player, and a piano key action has about ten moving parts for each note, mounted in neat rows.

Open the door of an organ case or organ chamber, and you face a complex heap of contraptions that somehow unify into a musical whole. There are bellows or reservoirs to store and regulate wind pressure, ducts to direct the wind throughout the organ, levers, switches, and wires connecting keyboards to valves, ladders and walkboards to allow technicians to clamber about inside. As it is the challenge to the musician to play the instrument with as little extra noise as possible, it is the job of the organ builder to make the machine disappear. The inherent mechanical nature of the instrument is minimized to allow the most direct communication between the musician’s brain and the listener’s ears.

Ernest Skinner, one of the most ingenious mechanical and tonal innovators in the history of organ building, invented the “whiffle-tree” expression engine. The origin of the whiffle-tree is the system of harnesses used to hitch a team of horses to a wagon that allows the force of the pull of each individual animal to be evenly added to the whole. Skinner made whiffle-tree motors with eight or sixteen stages depending on the size and glamour of the organ. They include large power pneumatics inside the machine connected to the marionette-like whiffle-tree that pulls on the shutter action, which are exhausted by a row of primary valves at the top of the machine. The motors are activated when you “close” the swell shoe, pulling the shutters closed. There is either a spring or a heavy counterweight with cable and pulleys to pull the shutters open when the motor is disengaged. To avoid the possibility of the shutters slamming closed, Skinner made the primary valve of the last stage smaller than the rest, constricting the exhaust, and slowing the motion of the shutters at the end of their travel.

While Mr. Skinner’s machine was effective at quieting the noise of closing shutters, I am reminded of a moment when operator error allowed expression shutters to make not only extra noise but visual distraction. A friend was accompanying a chorus on the organ in a music school recital hall and asked me to sit in on a rehearsal to listen for balance. She had chosen great registrations, so there was little to say there, but she was beating time with the Swell pedal, and since the shutters were fully visible as part of the organ’s façade, it was a huge distraction. We broke that habit.

Things that go bump in the night

In the 1980s and 1990s, I was curator of the mammoth Aeolian-Skinner organ at First Church of Christ, Scientist, in Boston, also known as “The Mother Church.” Dr. Thomas Richner was the organist, a colorful, diminutive man with a wry sense of humor and marvelous control over that organ with its nearly 240 ranks. My phone rang around eleven one evening, “Pee-pee” (he called everyone Pee-pee), “something terrible has happened to the organ. I closed the Swell box and there was such a crash.” That Swell division has twenty-seven stops and forty ranks including a full-length 32′ Bombarde, and there are four big windchests with four huge banks of shutters coupled together. I went to the church the next morning to find that the cable of the counterweight for the Swell shutters had broken, and several hundred pounds of iron had crashed onto the cement floor. Practicing alone late at night in a dark church, the poor man must have jumped out of his skin.

In the 1960s, organ builders were experimenting with electric motors to control the stops of slider chests, and one of our supply houses marketed Slic Slider Motors, grapefruit-sized units with a crank arm on top that rotated 135-degrees or so from “on” to “off.” I suppose they were among the first units to work reliably in that application, and lots of organ builders used them. The travel was adjustable, and they worked quickly. But the noise was unmistakable, schliK-K-K! I remember as a pre-organ builder teenager sitting in a big church listening to an organ recital, wondering what all that noise was. After a particularly large and noisy registration change, the mentor who had brought me leaned over and explained it. That was before I knew Inda Howland, but I am sure she would not have approved.

In the early 1970s, Laukhuff, the prominent German organ supply firm that recently and unfortunately ceased operations, developed a double-acting solenoid slider motor. It was housed in a steel case, and there were steel “stops” with heavy rubber bumpers attached to the shiny central shaft to limit the travel of the sliders. I maintained several organs that featured those motors. They worked beautifully until the rubber bumpers crumbled and fell off after thirty or forty years. The motion of the powerful motors was now limited by steel-on-steel, and they made an impressive hammer-on-anvil sound as they operated. I made a supply of replacement bumpers to keep in each organ punched out of woven green hammer-rail felt with a slit cut to the center hole so they could be popped onto the shaft without dismantling the motor.

Going out with a bang

During the “organ wars” of the 1960s and 1970s, “tracker detractors” chortled, “if it clicks and clacks, it’s a tracker.” Fair enough—lots of tracker organs have action noise, especially older ones. But the thousands of “pffts” from an electro-pneumatic organ are also often audible from the pews. Modern tracker actions have Delrin and nylon bushings to replace the metal-on-wood systems found in older organs and carbon-fiber trackers that do not slap at each other like traditional wood trackers.

It is easy and relatively inexpensive to include muffler covers to quiet electro-pneumatic actions, but I have often been in organs where a previous technician left the covers off for convenience, allowing the action noise to be clearly audible. And tremolos: how many of us have heard them set up a Totentanz with reservoir weights jumping and thumping and valves huffing and puffing? Screw down those weights before they bust a gusset in a reservoir and build a box around that pufferbelly. It is not helping the music.

Along with space-age materials that allow us to build quieter actions, we have space-age lubricants to keep things running smoothly. A squirt or two and the squeak is gone, and the part moves effortlessly. But there was a spray lubricant used widely in the early 1970s that worked fine for a generation but turned gummy as it aged. Several prolific organ companies used it to lubricate the sliders of windchests, and stop actions failed as the stuff gummed up the works. I had several jobs that involved removing the pipes, taking up toeboards and sliders, cleaning off the old goo with solvents, and spraying on a new lubricant. I hope the stuff I used will last longer than the original. There is an old joke about it being easy to spot the organ builder as he walks through town because all the dogs follow him, attracted by the smell of mutton tallow he used to grease the skids.

Part of the magic of the pipe organ is its ability to move from a whisper to a roar and back again. Part of the challenge of effectively playing an effective instrument is to preserve the music itself as the only noise. I’m grateful to Inda Howland for her keen observation of the bombast of my twenty-year-old self. Let the music play.

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.

The Organ Clearing House goes to the movies.

In July 2010 Sony Pictures released Salt, a film directed by Phillip Noyce, starring Angelina Jolie and Liev 
Schreiber. Ms. Jolie’s character is Evelyn Salt, a CIA agent accused of being a Soviet spy. Salt sets out to prove her innocence, and lots of people get hurt. One of the pivotal moments is the funeral of the American vice president held at Saint Bartholomew’s Church on Park Avenue in New York City. The church’s organist and choirmaster at the time, William Trafka, and the Saint Bartholomew’s Choir would perform a bit of Gabriel Fauré’s Requiem in D Minor as the vice president’s dear friend, President Matveyev of the Soviet Union, ascended the pulpit to deliver the eulogy. Salt would enter the church’s crypt from an adjacent subway tunnel, sabotage the organ’s wind and electrical systems creating a roaring disturbance, then detonate explosives that would deliver the pulpit, president and all, to the crypt where she would shoot him. Just another day in the life of a church.

Leslie Rollins, the film’s set decorator, read an article in The New York Times about the restoration by Quimby Pipe Organs of the organ at the Cathedral of Saint John the Divine, and the Quimby people recommended the Organ Clearing House to decorate the set of the basement mechanical room for the St. Bart’s organ. Leslie invited me to the film’s offices in New York’s Chelsea neighborhood where he led me into the world of make-believe-turned-believable, which is the motion picture industry. The office walls were festooned with concept drawings of the dozens of sets that would be built, and he led me through the story so I could understand the role of the set we would create.

I described the behind-the-scenes functions of a large pipe organ including the blower and adjacent static reservoir and an array of electro-pneumatic-mechanical switching equipment. Since this would be an active operating set, I arranged to take Leslie and a couple people from Special Effects (SFX) to visit a nearby church to see that kind of equipment in operation. As is usual when the blower was turned on, the static reservoir expanded about six inches. They were disappointed—it wasn’t dramatic enough. I told them that while I did not want to build anything that would not be credible to another organ builder, I agreed that we could fashion a mock-up regulator with a more dramatic range of motion.

We provided a large blower from our stock and a huge array of organ electrical equipment borrowed from the yet-to-be-restored W. W. Kimball Co. organ at Boardwalk Hall in Atlantic City, New Jersey (in return for a nice contribution to the restoration of that organ), and I built a hilarious double-rise reservoir using two-by-fours for top, bottom, and middle frames and ten-inch-wide ribs cut from plywood. I made the usual canvas hinges all around but only put leather on the three sides that would be exposed to the camera. Rather than the measly six-inch rise of a normal organ reservoir, this thing opened close to thirty inches.

The dozens of sets were built in a complex of unused aviation hangars in Bethpage, Long Island, previously owned by Grumman Aerospace Corporation, the site where the Lunar Excursion Module (LEM) that landed astronauts on the moon was built. The crypt had ribbed arched ceilings, much fancier than the actual basement at Saint Bartholomew’s, made of two-by-four frames and Styrofoam painted to simulate stone masonry.¹

In April 2009 my colleague Amory Atkins and I gathered the blower and wind-system components along with metal windlines and regulating valves. I drove a truck to Atlantic City to collect the switching machines, and we met in Bethpage to assemble the fabrication. Once the big pieces were in place, we were joined by SFX who added the equipment that would animate the scene. Evelyn Salt would jump off a moving subway train, vault through an opening into the crypt, shoot the chain for the regulating valve causing the reservoir to rise dramatically, and shoot the switch stack causing a noisy explosion (way more sparks and smoke than a usual 12-volt DC organ system could produce). The organ above would roar into a mass cipher, the congregation would panic, Salt would scatter explosives under the foundation of the pulpit, and Bob’s your uncle. The set decorating team included a young hippie woman who floated a cart of art supplies about the place followed by a big floppy golden retriever. It was her job to make things look old. I gave her photos of a “real” organ blower room with the usual accumulation of dirt, dust, spider webs, and debris, and she worked her magic to make it look authentic.

I showed Leslie the completed set and described what Ms. Jolie would have to do to put all that in motion. Bewildered, he asked me to come back in a couple weeks for the filming of the scene so I could explain it in person. When I arrived, I learned that they were running behind and did not know exactly when I would be needed. Could I stay around and be ready at a moment’s notice? For two days I watched the various actors take and retake their scenes, building the movie a few seconds at a time. Phillip Noyce moved from set to set with an entourage of aides with clipboards and flunkies who carried his chair and computer monitors around. I watched Angelina Jolie vault through that opening into the crypt dozens of times—she was doing her own stunts. Then came an urgent message over the public address system, “Organ guy to the crypt, organ guy to the crypt.”

Angelina Jolie came into my little sanctum with hand outstretched, “Hi, I’m Angie.” I explained the set-up, “You shoot this chain;” “I can’t shoot that;” “I’ve seen you shoot.” Mr. Noyce invited me to sit with him to watch the take onto his monitor. “When I point at you, you yell ‘action’!” (My big moment.) Leap, shoot, whoosh, shoot, flash, blam, roar. Noyce hollered, “Fantastic, cause and effect in one shoot.” And that was it. Angie jumped out that tunnel at least thirty times, but she shot my chain in one try.²

With the shoot complete, we broke down the set and returned all the gear. I was on the job for about three weeks. I saw the setup outdoors that would catapult a car off a highway bridge. I witnessed actors who were playing small roles asking Angie for autographs. I saw Angie and Brad Pitt coming and going from her trailer. I learned that 150 carpenters were employed for that one film. And when I saw the completed film, I was struck by how much effort went into building and decorating that set for a scene that lasted just a few seconds. If you watch the movie, do not take your eyes off the screen once you see Salt on a subway, or you will miss it. I was disappointed to learn that you had to be a $100,000 vendor to make the credits. I mentioned that I could have charged that, but it was too late.³

It is easy to stream Salt. I watched it a couple nights ago on Netflix. I saw the completed sets for the barge, the tunnel, the CIA stairway, the office where Salt made a bazooka from an office chair, the hotel room, the Bolt bus, and the North Korean prison.

I happened to ride past Saint Bartholomew’s in a taxi during the filming of the big explosion scene. There were dozens of fire trucks, police cruisers, and ambulances hovering about, and a crowd of extras big enough to create a church-filling congregation of mourners. I am sure the Fire Department of New York was a $100,000 vendor. They must have made the credits.

Let’s take it live.

My friend Angie got dozens of tries to make the perfect leap from the subway tunnel to the crypt of the church. Actors in live theater get one. They may have twenty or thirty performances, more if they are in a well-funded big-city show, but each night they get one chance for each moment of magic.

The other night, Wendy and I saw a production of Cabaret at the Barrington Stage Company in Pittsfield, Massachusetts. The venerable show has a cast of twenty-one, ten of whom are in the chorus known as the Kit Kat Ensemble—the Kit Kat Club is the main set for the show. The story is set in the jumbled unraveling of the cultural life of Berlin in the years leading up to Nazi domination and the start of World War II, where the Kit Kat Club is a refuge for a large part of the population we know today as LGBTQIA2S+, in a time when such self-identification was not understood or accepted by those outside the acronym. The atmosphere in the Kit Kat Club was of forced hilarity, longing, and sexual confusion.

The superb ten-piece orchestra was sitting on a tiered bandstand on stage, just as you would expect a band to be played in a dance club—think of Ricky Riccardo’s band on I Love Lucy—and the energetic dancing swirled around them. Sometimes a lead character would leap into the band to hide, lights out, as the scene was changed. Sometimes a member of the band was soloed-out, spotlight and all. And during the song “Tomorrow Belongs to Me” at the end of the first act, the lead keyboard player, who was also the conductor, scooped up a gleaming white accordion and led the ensemble to the front of the stage singing her heart out.

Cliff Bradshaw, the traveling, struggling American novelist, hopes to build a life with Sally, the club’s marquee singer. Herr Schulz, the neighboring fruit vendor, dreams of marrying Fräulein Schneider, the spinster landlady who rents rooms to the various women of the ensemble and tries to turn a blind eye to the parade of sailors coming and going in her house. Then Cliff realizes that he has been used as a courier for the Nazis. Herr Schulz is revealed as a Jew and Fräulein Schneider realizes that she cannot risk her scant living and safety by marrying him. Some characters deny the situation, some try to exploit it, and some are propelled by the frenzy of alcohol, drugs, and sexual freedom to the exclusion of everything else. The emcee is the heart of the show, inciting and weaving the intrigue, hinting at the macabre, reveling in the confusion, and has the longest list of dance steps, acrobatics, complex songs and monologues, costume changes, and sinister gestures of all the characters.

We were attending one of the last performances of the three-week run. As we arrived at the theater, we read that the curtain would be delayed. Sometime around the scheduled curtain time, it was announced that the actor playing the emcee was unable to appear, and the understudy was hard at work with the cast doing a last-minute blocking rehearsal on stage. A half hour later we entered the theater. “Willkommen,” the bawdy opening number, blasted onto the stage, and for two-and-a-half hours we watched, yelled, and whistled in awe as the understudy and heretofore chorus member James Rose (she/they), tall and slender with past-shoulder-length hair, brought the emcee to life in their first and last-minute crack at the role.

I am sure that Wendy and I have seen understudies taking on a role before, perhaps sometimes at the last minute, but not a role as complex as this. I doubt that this performance will go fuzzy in my memory but will join the file in my memory titled “Unforgettable.” The emcee is central to most of the songs and dances, and Rose’s interpretation included endless sinister, sensual, sensuous motions of their extra-long, extra-flexible fingers. I have no idea how much rehearsal time she had with that role, but she certainly spent a lot of time thinking and preparing for it. I would love to have been a fly on the wall for that last-minute rehearsal while we were waiting outside for the house to open; it must have been a very dramatic hour.

Art of the moment

In last month’s issue of The Diapason, I wrote about our recent trip to Athens, Florence, and Bologna during which we visited as many museums as our stamina would allow—more, in fact. We reveled in the timeless works by Giotto, Michelangelo, Caravaggio, and Ghiberti, as art lovers have for 500 or 600 years. If we are still able, we could go back and see them again in twenty years. You lean in to look at brush strokes, chisel marks, dappled sunlight, and facial expressions. Favorite souvenirs from the trip are the two-inch pieces of Carrara marble that I picked up from the roadway when we visited the quarry that was the source of stone for the sculptures of Michelangelo along with many other artists. What makes those stones magical are the hundreds of tiny, shiny facets that sparkle when I turn them under my desk lamp, the quality that breathes life into those monumental statues.

The performing arts are different. A piano sonata, an aria, a symphony, a Broadway show, or a hymn happens in real time. If the artist misses a piston or flubs a note, or a couple dancers run into each other, the moment vanishes but stays in memory. Cooperative music-making is one of the high points of the human condition. A symphony orchestra is a spectacular achievement, a choir is equally special, especially considering that it is just human voices. An opera or the musical we saw the other night is multi-dimensional, including singing, dancing, instrumental music, and live drama, and that production is a real romp—there is something happening onstage every second.

This notice was included as an insert in the playbill for Cabaret:

Barrington Stage wants to remind you that this is live theater; and for some of us, it can be church. Just like in church, you are welcome to come as you are—to hoot and holler or to sit quietly in reverence. Worship and engage however you feel most comfortable. Laugh audibly and have natural emotional and sometimes vocalized responses if you feel it. Just remember that while it’s okay to engage, we should aim to neither distract nor thwart the performance.

I know I hooted a few times, and probably hollered, too.

§

On November 14, 1943, the twenty-five-year-old Leonard Bernstein stood in for the ailing Bruno Walter at the last minute, conducting the New York Philharmonic Orchestra at Carnegie Hall, and his career took off like a rocket. James Rose’s performance the other night was other-worldly, and more breathtaking as she was a last-minute fill in. I wonder what was going through their mind during that curtain-delaying rehearsal. During the ovation at the end of the performance, fellow cast members were expressing their admiration, offering quiet, affectionate congratulations, and deferring to Rose for extra solo bows. It was a thrilling performance of a chilling character. The arts matter.

Nota bene

While I took hundreds of photos while working on Salt that show the various sets under construction, we were required to sign a non-disclosure agreement that barred us from publishing photographs taken on the set, and expressly forbidden from photographing the actors. Even though it was almost fifteen years ago, and though I would love to share some photos here, I will stick to the agreement I signed.

Notes

1. A different set for the film used another neat “faux-trick.” Late in the film, there is a scene where the American president is hustled down an elevator to a secure emergency facility deep underneath the White House. The tunnel between the elevator and the facility was ribbed, the ribs were made of swimming-pool noodles covered with thick spray paint.

2. Burt Dalton, foreman of SFX crew, won an Oscar for his work on The Curious Case of Benjamin Buttons the year before. I was impressed by his status on the set. When he walked by, people whispered in awe and respect.

3. Follow this link to see listing of cast and crew for Salt: https://www.imdb.com/title/tt0944835/fullcredits/?ref_=tt_cl_sm. There are over 180 cast members from Angelina Jolie as Salt to Zoë D’Amato, mourner. Scroll past the cast to see the crew, which included twenty-three makeup technicians and hundreds of others in the art department, sound department, special effects, visual effects, stunts, costumes, editorial, location, etc. It takes hundreds of people to make a movie like this.

Everything’s under control.

It is early March, and there is two feet of snow on the ground in mid-coast Maine. Each foot came from a different storm. The bottom foot has a frozen crust making an awkward crunch halfway through. Farley the Goldendoodle’s legs are about twenty inches long, and he is just heavy enough to crunch the buried crust, so it is hard for him to do the things that dogs like (and need) to do outdoors.

It is overcast and snowing lightly now, and the wind is blowing frantic patterns in the water. We will be setting the clocks ahead this weekend, so it is about time to start thinking about the upcoming sailing season. On a sailboat, the sails are controlled by lines (they are never called ropes). Halyards raise and lower the sails, and sheets trim the sails in and out, adjusting their position relative to the wind. You might think that “sheet” refers to the sail, but you would be wrong.

Our sheet was new when the boat was built in 1999, and this was the winter to replace it. It is over a hundred feet long as it passes through a five-to-one ratio of blocks (pulleys) to provide the leverage needed to manage the large sail. I bought a beautiful piece of line, supple enough to manage all those turns without too much friction, and threaded it through the rig, ready for the first sail of the spring.

Besides halyards and sheets, all we need to control the boat (not counting the engine) is the steering gear that has a wheel, a rack-and-pinion gear system, and a rudder. That is called the helm, as in “Grandpa’s at the helm.” The more sails you have, the more lines and the more complex things seem. A large, square-rigged ship might have thirty or more sails, each with two sheets and two halyards, all running through countless blocks. It seems bewildering, but it is not nearly as many moving parts as a two-manual pipe organ with tracker action.

New-fangled

The introduction of electric actions in pipe organs around the turn of the twentieth century concerned organists who felt that electric actions would be slow and not as sensitive to the whims of the musician as the mechanical action that was in every organ until about 1890. I can make an argument for not being as sensitive—a well-built and carefully adjusted tracker action allows a special level of control that surpasses the on-off functions of electric contacts, but even the most intimate and sensitive of tracker actions commits the musician to playing a musical instrument by remote control.

A violinist cradles her instrument under her chin and generates tone with her touch of the bow against the strings. A clarinetist puts the instrument into his mouth and generates tone with the muscles inside his mouth coupled with air pressure from his lungs. It does not get any more intimate than that. The organist is either pulling on levers or flipping switches to control tone that is generated by a remote wind supply blowing through hundreds of static instruments, each of which can only play one note at one volume level. While a flutist can shape a phrase with intimate and intuitive breath control, for the organist any artistic nuance is achieved by purposefully operating a device—pulling on a stop, moving an expression pedal, changing keyboards. Altering the spacing and timing of notes and chords is about the only intuitive tool available. 

With the development of electric actions, organ builders introduced innovations to give the organist more control over the instrument. I marvel especially at the first combination actions. Some were contained inside the organ console, such as those built by Casavant or Ernest Skinner’s stupendous vertical selectors, and others were remote, stacks of machines placed in adjacent rooms or basements, connected to the console by cables containing hundreds of conductors. 

Think about a three-manual console with a hundred or more stop controls and a remote combination action. There are three sets of sixty-one wires and one of thirty-two for the keys and pedals. That is 215 wires leaving the console. Add forty pistons, and that is 255 wires. Add stop actions and on-off wires so pistons can operate the console’s many stop knobs, that is 555 wires. Add forty-eight for three sixteen-stage expression motors, add two for “bride signals.” You get the picture.

Think of all that multiplicity in the light of the four-manual, seventy-six-stop organ Mr. Skinner placed in Saint Thomas Church in New York City in 1913. It had seven pistons for each of five divisions (no generals), and a set button. That console and its related equipment was a commercially available, user-programmable binary computer built of wood, leather, and bits of metal built in Boston in 1913. I wonder if anyone still arrived at church on Sunday in a horse-drawn carriage in 1913? 

Artifacts

I have a collection of trinkets that reminds me of past episodes that I have kept for decades in all the places we have lived. In a top bureau drawer in a little monogrammed leather box given to me by my godmother when I graduated from high school, I keep my draft card from 1974. (The draft call ended in December 1972, but eighteen-year-old men had to register until April 1, 1975.) On top of that bureau, I keep a mug with the logo of Bohemian Trucking in Las Vegas, filled with pens and pencils. Bohemian Trucking bailed the Organ Clearing House out of disaster at the last moment when a moving company abruptly canceled the five semi-trailers we had arranged to move the Möller organ, Opus 5819, from Philadelphia to the University of Oklahoma for the American Organ Institute. Bohemian stepped in on a day’s notice with those five trucks. They are out of business now, but the mug is a fun reminder of a very dynamic couple of days. I remember vividly the phone call from the moving company that stiffed us. I was waiting at a baggage carousel at the airport in Philadelphia, getting ready to load the organ the next day.

I am not proud remembering my very public, very angry reaction. I am sure I frightened some people.

One trinket that stands out usually lives on top of a bookcase in my office. It is an eighteen-inch chunk of the console cable from Trinity Church in Boston’s Copley Square. It includes cables from three generations of that organ all bundled into one: the original 1926 four-manual, sixty-one-rank Skinner Organ Company Opus 573 located in the rear gallery; Aeolian-Skinner Opus 573A, which was a new three-manual, fifty-rank organ installed in the chancel in 1956; and Aeolian-Skinner Opus 573-ABC, which was the 114-rank combination of both chancel and gallery organs finished in 1961. There were electro-pneumatic coupler actions in the console cabinet, but all the switching and relays that controlled pitman and unit windchests of the nine divisions, the combination action, and controls for accessories like tremolos and expression were in a basement room directly below the console. Eighteen inches of that cable weighs almost eight pounds. I do not remember all the details, but doing math as I did earlier for a mythical one-hundred-stop organ, this cable has somewhere between 1,400 and 1,500 conductors. It looks like more.

The 1926 cable was made by Skinner using white cotton-covered wire, wrapped in friction tape. (I like to call it hockey tape.) The second cable is again all white conductors, but it was commercially made as a cable with a woven cloth sheath. The newest one is something like what we use now, vinyl-clad cable with conductors insulated with color-coded PVC. Jason McKown, the old “Skinner Man” who maintained the Trinity organ for fifty years before me, told me that this was one of the first organs Aeolian-Skinner wired with color-coded cables, and the guy who did most of the wiring was colorblind so even with the color code, he did the wiring the old-fashioned way, ringing out each conductor separately. This artifact is my reminder of one of the more dramatic days in my career.

It was a hacksaw.

The double organ at Trinity Church has always been heavily used by brilliant organists who know how to give it a workout, and by around 1990 all the electro-pneumatic switching and combination actions in that basement room were wearing out. Phosphorous bronze contacts were breaking regularly, causing dead notes and cross ciphers as broken contacts fell inside the vertical switches causing clusters of notes to play simultaneously, a great way to annoy organists. There were also hundreds of switches in the chancel and gallery organ chambers in similar condition.

As I was curator of the organs, my Bishop Organ Company was engaged to install a solid-state control system. The whole process would be accomplished without the organ missing a Sunday or Friday noon recital. As I look back, I must have been nuts to agree to that, but I sure remember that the rector was not giving any ground. He was good at not giving ground. I worked with Brian Jones, the organist and director of music, to develop a scheme that involved buying a console for temporary use while the original console went to the workshop for renovation.

We built new stopjambs for the temporary console with layout identical to the originals, and wired all the keyboard, stop, piston, and expression outputs with new cables fitted with connectors. We pre-wired the hundreds of rows of switches in the remote room and chambers with new color-coded cables fitted with connectors, we hung the SSL control boards in all locations, and pre-wired all the inputs and outputs to and from those boards. With dozens of pitman and unit windchests, there were thousands of connections in the organ. There were more than 250 cables, each with a hundred conductors. Most of the rows were either sixty-one or seventy-three notes, so a lot of conductors were left over as spares, but you get the idea.

When every new connection had been made, all the connectors organized, and the organ was still playing on its original wiring, we brought the temporary console to the church. All six of us were ready when the 6:00 p.m. service ended that Sunday night. As the congregation was leaving, we fanned out across the building with our assignments. I gave myself the task (privilege?) of cutting that console cable. I used a hacksaw. It was breathtaking. I think it was the most thrilling and dreadful moment of my career. Two swipes of that saw blade and the organ was unplayable.

We dragged over forty feet of the old cable out of the conduit, more than a hundred pounds of copper wire, put the temporary console in place, ran the new cables through the conduit, and set about plugging in all those cable connectors. As each seventy-three-note switch was plugged in, the original organ wiring had to be cut away, and old and new wires had to be wrapped and dressed to keep the job neat. Working against the deadline of the Friday recital (would the organist have any time to practice?), we were ready to turn the organ on by Wednesday morning and play it from the new console. Every organ builder knows the rush of feelings when you turn that switch for the first time.

It played.

It was not perfect, but it played. SSL systems had an odd configuration with stop action and key action on opposite polarities of the organ’s direct current. In the original Skinner and Aeolian-Skinner wiring, all functions of the organ operated with positive “on” impulses and negative commons. SSL had the stop actions with negative “on” and positive grounds, so our preparation had to include running positive commons to all the stop actions, and during the switchover week we had to separate the stop action commons from those on key actions. We had the polarities of the stages of expression motors wrong. The first time we tried to operate an expression pedal, we blew a row of transistors. It was lucky that in those days we still had neighborhood Radio Shack stores and could quickly buy new transistors and solder them to the SSL boards. It cost just a few dollars, a few hours, and a big helping of anguish.

The conductors inside all those cables are arranged in groups of ten, each with a solid color and a “stripey” color—white with blue stripe, blue with white stripe, white with orange, orange with white, white with green, etc. Blue, orange, green, brown, slate repeats with group colors. When you finish those five pairs with white, you move to red with blue, etc., then black with blue, etc., then yellow with blue, etc., then violet with blue, blue with violet—groups of ten with white, red, black, yellow, violet. The first fifty wires are wrapped with blue, then you start over with white with blue. The pattern can be infinite. The point is that you can wire each end of the cable by yourself according to the code, rather than the old way requiring two people using a buzzer or a light to find the opposite ends of each wire.

All the pre-wiring on the temporary console, the remote room, inputs for each keyboard and stop to the SSL boards, and outputs from the boards to each of the hundreds of switches to the windchests was done by two of my employees. We generally used 32-pair cables that are specially made for pipe organs as they have enough conductors for sixty-one notes plus three spares, but since many (most?) of the windchests and ranks in the Trinity organ have seventy-three (super-coupler extensions) or more notes, we used 50-pair cable throughout the instrument. In 32-pair cable, the code goes only as far as yellow with blue, blue with yellow, the thirty-first and thirty-second conductors, then starts over with white with blue. The 50-pair cable goes through all fifty color combinations before starting over. I bother to explain that because those two people who were my wiring wizards were less used to 50-pair cables, and it turned out that one of them could not tell between the violet/blue–blue/violet pair, notes 41 and 42, the “E” and “F” above “soprano C.”

I sent the team across the organ double-checking and correcting those two conductors wherever they were reversed. We spent Wednesday and Thursday correcting the glitches. The recitalist practiced on Thursday night, and like every Friday morning during my tenure there, I tuned reeds until 10:00, the recitalist warmed up, and the audience arrived.

The rest was simple. We renovated the original console with electric drawknob motors, pre-wired it now that we were so good at it, brought it back to the church, and plugged it in. Plug-and-play for an organ with nine divisions. It took less than a day including the round-trip drive from the workshop twenty-five miles away.

I do not have an accurate count of how many conductors there are in that organ, how many violet/blue pairs were reversed, or how many transistors burned. I do not remember how late we worked into each evening. I sure do remember kneeling behind that console at 7:30 on a Sunday evening with a hacksaw in my hand, drawing breath, and hacking away. I was in my mid-thirties. I guess I thought I knew a lot. I had a few moments that week when I smelled smoke. I am sure I had moments that week when I smelled disaster. I know how pleased we all were when the organ played from the first moment the blower was on. Brian was congratulatory, and I never heard a word from the rector. 

Didn’t miss a Sunday.