In the Wind: Take good care

String too short to save

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

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

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

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

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

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

He polished up the handle of the big front door.

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

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

Totally tubular

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

Parts is parts.

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

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

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

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

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

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

Material handling

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

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

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

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

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

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

Perspective

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

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

Made right here

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

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

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

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

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

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

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

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

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

Potter at work

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

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

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

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

Will it float?

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

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

Back to its maker

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

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

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

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

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

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

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

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

Where it all begins

When I was growing up, my family had a summer home on Cape Cod where we grew enamored by a brilliant potter about five miles away. Scargo Hill Pottery was founded by Harry Holl, and over fifty years later his daughters still make the characteristic shaped dishes, mugs, and vases we grew to love. Harry worked with white porcelain that he accented with dark spots made by mixing the black sand from a specific nearby beach into his clay. He accented them with vibrant glazes. Our household and those of my siblings are rich with Harry Holl pieces; it is lovely to eat daily meals off such beautiful art and to have such ornaments on our walls and shelves.

From its beginning Scargo Hill Pottery has had a wonderful, almost spiritual side. There is a row of potter’s wheels in a sunlit spot with a translucent fiberglass roof and no walls, where you can stand and watch the artists create their products. I still think it is magical to watch a turned shape emerge from a lump of clay and become a useful vessel. From my earliest teenage years I have been in love with places where beautiful things were made. On many a summer evening, we piled into the car after supper to visit Harry and his troupe. The lovely outings were capped by a stop at Sea Breeze soft-serve ice cream conveniently located along the route.

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The 150-acre summer estate of sculptor Daniel Chester French (1850–1931) is a couple miles from where we live in Stockbridge, Massachusetts. French is perhaps best known for two iconic public sculptures, The Minute Man statue in Concord, Massachusetts, near “the rude bridge that arched the flood,” and the monumental statue of a seated Abraham Lincoln in the Lincoln Memorial in Washington, D.C. He bought the property in 1896 and immediately commissioned the construction of a studio that became his principal workspace for the rest of his life. At that time there was train service from New York to Stockbridge; the Stockbridge station, long out of use, still stands just a couple miles from Chesterwood.

The studio is situated close to the house and has large glass windows providing plenty of natural light inside that feature broad views of Monument Mountain and the rest of the southern Berkshires. The principal work room is twenty-nine feet by thirty feet with twenty-six-foot-high walls allowing enough space for monumental equestrian statues. Since most of French’s work was to be installed outdoors, the design of the building included a working platform on railroad tracks with large doors that allowed him to move a massive work in progress outside so he could view it in natural light. He was so eager to work in the beautiful new space that he moved in two weeks before it was complete. The building included a reception room where he could receive potential clients and where his family had afternoon tea when the weather would not permit using the house’s grand south-facing porch.

The Minute Man was completed in 1875 for the centennial of the start of the Revolutionary War, before French acquired Chesterwood, but the Lincoln Memorial was completed in 1920. French designed Lincoln’s statue at Chesterwood, and a six-foot model is on display there. The full-scale statue was carved by the Piccirilli Brothers whose studio was on 142nd Street in the Bronx, New York. A four-foot bronze statue of a winged angel by Daniel Chester French, The Spirit of Life, stands in a portico at Saint Paul’s Episcopal Church in Stockbridge.

A visit to Chesterwood is an inspiration. It is thrilling to think of the wealthy and powerful people who traveled there to commission public art, and wonderful to imagine the brilliant and prolific artist toiling in the lovely studio in that bucolic setting, surrounded by family and friends.

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Another iconic artist’s studio is within walking distance of our house in Stockbridge. Norman Rockwell had been living in Vermont when his wife began treatment at a prominent psychiatric hospital in Stockbridge, and Rockwell moved his family there in 1953. His first studio in this town was behind a large plate-glass window in the central storefront of Stockbridge’s Main Street, directly above the Back Room Rest, familiarly known as Alice’s Restaurant of Arlo Guthrie fame. He later built a free-standing studio with plenty of natural light on South Street. When the present building of the Norman Rockwell Museum was opened in 1993, the studio was moved to the new site where museum visitors can go inside to see Rockwell’s easels, paints, brushes, props, and tools.

Many hundreds of Norman Rockwell’s large-scale paintings were featured on the covers of The Saturday Evening Post and are inscribed in the artistic minds of millions of people around the world. I have been moved many times by sitting on the bench and playing the keys upon which the giants of organ music sat and played—Widor, Dupré, Saint-Saëns, Fauré, and so many others. It is equally moving to see the stool on which Rockwell sat while painting his beloved three-dimensional self-portrait, his iconic Rosie the Riveter, and The Runaway.

Our place in Stockbridge backs up to the cemetery where every morning I walk Farley the Goldendoodle through the cemetery, past Norman Rockwell’s grave to the adjoining Naumkeag estate, a great place for him (Farley) to be off leash for his morning constitutional. Norman is there with two of his wives, his gravestone festooned with tubes of paint, paintbrushes, and little trinkets left in tribute to his marvelous career and influence on our cultural life. Our granddaughter has been swept up by Norman-mania, being sure to visit him each time she visits us.

That Ingenious Business

In 1990 the Pennsylvania German Society published a book by our late colleague, friend, and organ builder, Raymond Brunner about the Pennsylvania German organbuilders Philip Bachman and David Tannenberg, among many others. These were some of the first organbuilders active in the United States, and a few authentic examples of their eighteenth-century American-built organs are still extant. As the organ was the most complex device built by humans at that time, the phrase “that ingenious business” evolved around that local industry. Now we are surrounded by technological marvels—no eighteenth-century organbuilder could have imagined mobile phones, flat-screen televisions, or nuclear submarines, but the pipe organ remains one of our fascinating achievements.

Among my many pleasures of working with the Organ Clearing House is visiting the workshops where pipe organs are built. We have working relationships with many of the country’s fine organbuilders as we help them with their projects, providing truck transportation, rigging and hoisting, assembly and disassembly. I have been in dozens of organ shops both here and abroad, and I always marvel at the creativity and dedication of the people in them. My first shop visits were open houses at Fisk and Noack in the 1970s when I was in high school. Organbuilder George Bozeman was an early mentor. I sang with his wife, Pat, in the choir at my home parish, and they were generous, taking me to those magical places to see organs nearing completion and ready to be dismantled and shipped. My high school organ teacher John Skelton also shared those wonders with me.

My first experience working in an organ shop was the summer of 1975, between my freshman and sophomore years at Oberlin, when I spent those months in the workshop of Bozeman-Gibson & Company. The shop was in Lowell, Massachusetts, in a building previously occupied by organbuilder Rostron Kershaw, and I spent my first day as a nascent organbuilder in the parking lot with sawhorses, façade pipes, Zip-Strip, hose, bucket, and rubber gloves. Oh, the glory of it. The parking lot was shared with a guy who transported chickens on a flatbed truck stacked high with wooden coops. I do not think he raised the chickens. I guess you would say he was trafficking in chickens, but the truck clattered in and out, and he was always happy to take the sawdust from the dust collection system to line his coops. Once when the bin was empty, he asked if we would plane some wood.

That summer, the company was working on the restoration of the wonderful 1848 George Stevens organ in the First Church of Belfast, Maine, and the installation of a new organ in the Federated Church of Castleton, Vermont. What an adventure it was for a nineteen-year-old enthusiast to spend the summer driving around New England, staying in motels, eating with a meal allowance ($1.50, $2.50, $3.50 for breakfast, lunch, dinner), and having my first hands-on experiences with organs. I returned the following summer and helped install the Bozeman-Gibson organ on Squirrel Island, an exclusive summer community off the Maine coast near Boothbay Harbor, six miles as the crow flies from our house in Newcastle.

Nearly fifty years later, I still marvel at the magic. I have a sense that it is improbable that we would be allowed, even encouraged to make something as otherworldly as a pipe organ. The variety of skills involved seems endless. An organbuilder is an architect, carpenter, woodworker, steel worker, electrician, leather worker, metallurgist, sculptor, acoustician, and musician. A comprehensive workshop houses familiar machinery like saws, drill presses, and planers, milling machines, and welders, and equipment you are not likely to see elsewhere like the cauldrons for melting soft metals, and especially the tables for casting the long sheets of metal used to make organ pipes.

François-Lamathe Dom Bédos de Celles de Salelles (1709–1779, we know him familiarly as Dom Bédos) was a Benedictine monk and organbuilder who published a monumental treatise, L’art du facteur d’orgues (The Art of Organbuilding) in 1778. Its volumes are packed with elegant engravings showing all facets of the trade including tools, workbenches, mechanical actions, wind systems, windchest layout, and clever exploded views of the interior of a complete organ. The cauldron and casting table are clearly illustrated, just like those found in modern workshops. I imagine that Dom Bédos built lovely big bellows to help tend the fires under his melting pot. Of course, today’s organbuilders do not have to stoke wood fires to melt their metal; a gas burner does the trick in a trice. Flipping through the pages of the good monk’s treatise shows how little has changed in the craft in nearly 250 years.

But how much has changed

Aristide Cavaillé-Coll (1811–1899) is revered for the tremendous legacy of pipe organs his company produced for such churches as Notre-Dame and Saint-Sulpice in Paris, but along with over 500 instruments he was honored for the invention of the circular saw blade. How we take them for granted now. I still have the table saw I bought in 1987 when I started the Bishop Organ Company, and I have ten or fifteen circular blades for it, some of which have specialty uses. Most of them have carbide steel tips on the teeth that stay sharp through miles of cuts. Think of spending a day making thousands of wood trackers, maybe ten feet long with a cross section of 1.5 by 8 millimeters. You stand at that saw all day making cut after cut. It is monotonous, but you cannot let your mind wander because you really want precise cuts, and you want to keep your fingers. (I still have all mine after forty-nine years behind the saw.)

As repetitive and precise as that task is, besides the circular saw blade we have the added luxury of a shop-wide dust collection system. The good monk had none of that. He cut those trackers by hand. My mentor John Leek taught me to make long, straight saw cuts and to plane a board flat and parallel by hand before I was free to use the machines. It was a great learning experience. I hardly ever did that again, but that helped me imagine the time, effort, and concentration it would take to make an organ full of trackers by hand. Or think of making a keyboard by hand with sixty long straight cuts. When I worked for Angerstein & Associates in Stoughton, Massachusetts, in the 1980s, I built the four keyboards for the new console of a large organ in Corpus Christi, Texas, and I remember that the lowest few naturals of the bottom keyboard were a little wider than the others. I have not noticed anything like that in any of the historic organs I have visited. I recently had a fun exchange about that with the good people of the Red River Organ Company who maintain that organ now.

I had a root canal a couple months ago—not my first choice of how to spend a morning, but I had a good laugh with the endodontist when I told her that the smell of grinding my teeth reminded me of standing at a table saw cutting ivory or cow bone for keyboards. I was impressed by the array of teeny cutting tools she used with a compressed-air motor to drill so delicately into the roots of my teeth. She spoke softly to her assisting technician, “A 14, please,” “A 12, please.” Between gulps, I asked if those were bit sizes. Yes, but of course the numbers refer to length in millimeters, not diameter.

Drill sergeant

The art of organbuilding can be defined as the art of knowing where to put the holes. Each pipe in an organ needs at least two holes, a toehole to stand in and a rackboard hole that stands it up straight. In a slider chest, there are two more holes for each pipe, one in the windchest table and one in the slider. A ten-stop, sixty-one-note slider chest has 2,440 holes. Those in the windchest, sliders, and toeboards range from about ½ inch to 1¼ inches with some larger oval holes because the holes cannot be larger than the travel distance of the slider. The rackboard holes range from about ½ inch to 3 inches or more, with the largest pipes supported by felted “scallop” racks higher up on the pipe. Dom Bédos’s windchests did not have sixty-one note compasses, but he still had to drill thousands of holes just to hold up and blow the pipes. There are usually at least two holes in each key of a keyboard, one for a balance pin, and one for a guide pin. He built an organ with five manuals, each with fifty-six notes—that is 560 holes. He used a “bit-and-brace” drill with handmade bits. What skill, precision, and plain hard work 
was involved.

I have thousands of drill bits in my workshop—twist bits, multi-spur bits, Forstner bits (guided by the outside edge rather than a center pin), countersinks, and spade bits. To turn those bits, I have a little fleet of drill motors with rechargeable batteries and the drill press I bought with the table saw.

With your own eyes

If you have not already, I hope you all get to visit an organ shop sometime. Most companies that build new organs love to host open house events when an organ is ready to be shipped. Those events typically include food and drink, displays about how certain tasks and processes are accomplished, and the added excitement of visitors from the church where the organ is going. If you are planning a trip to an area that is home to an organ company, get in touch through their website or give them a call to ask if you might visit. At least they will put you on a mailing list for the next open house. There is an old gag about sausages—you might love to eat them, but you do not want to watch them being made. Watching the artisans at work in an organ shop will inspire your love of the instrument and will inspire your musicianship. It’s nothing like sausages.

O praise ye the Lord! All things that give sound;

each jubilant chord re-echo around;

loud organs, his glory forth tell in deep tone,

and sweet harp, the story of what he hath done.

—William Henry Baker

So goes the third verse of hymn 432 in The Hymnal 1982 of the Episcopal Church. It is set to a soaring tune by C. Hubert H. Parry that is supported with rich and compelling, even dramatic harmonies. The tessitura is high, which allows space for broad chords­—it is a doozey of a hymn that is a blast to sing. And of course, anyone who has devoted a big part of life to playing, building, and working on pipe organs will be a sucker for this one. It does not take a rocket scientist to think of punching General 12 to start that third line, and do not forget to play the comma after “organs” for all it is worth. It was Claude Debussy who said, “Music is the silence between the notes.”

On Saturday morning, October 6, several hundred gathered at New York City’s Church of the Heavenly Rest, proudly placed on Fifth Avenue between the Cooper Hewitt Smithsonian Design Museum (the former home of Andrew Carnegie) and Frank Lloyd Wright’s iconic masterpiece, the Solomon R. Guggenheim Museum, for the memorial service of Steven Earl Lawson. Steve was the assisting organist at Heavenly Rest for twenty-one years, and a tireless active member of the New York City Chapter of the American Guild of Organists. You can read his obituary in the October 2018 issue of The Diapason, but it bears repeating that he has made contributions of inestimable value to the organ world through his creation of the New York City Organ Project, which chronicles hundreds (thousands?) of pipe organs in New York City, including specifications, photographs, and histories accompanied by histories of the buildings and parishes. For example, take a look at http://www.nycago.org/Organs/NYC/html/HeavenlyRest.html and see what Steve had to say about the organs at his church.

In addition to the New York City Organ Project, Steve contributed mightily to the Organ Historical Society Pipe Organ Database, where you can type keywords into a simple form and find documentation of thousands of pipe organs nationwide. Hundreds of us who work daily with pipe organs routinely reap the benefits of Steve’s dedication.

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Standing in that church last Saturday, surrounded by valued colleagues, I was moved to be reminded of the purpose of our work as organists and organbuilders. A tag-team procession of organists shared the bench, including Steve’s prolific and beloved octogenarian teacher, Wilma Jensen, each offering their talents in his memory. The large and talented choir, including many volunteers, gave freely of their autumn Saturday, singing a variety of beautifully chosen music including the sublime “Sanctus” from Gabriel Fauré’s Requiem. Fauré’s genius was evident in the shimmering ascending lines sung by the sopranos and later by the organ—vivid pictures of the freeing of a human soul to rest and life eternal.

It is hard work to devote one’s self to artistic expression. As you walk through a grand museum, you see countless examples of physical labor. I am not sure I have read anything about Renaissance painters suffering from carpal tunnel syndrome, but consider this: Peter Paul Rubens lived sixty-three years between 1577 and 1640. According to the catalog compiled by Michael Jaffé in 1989, there are 1,403 works attributed to Rubens. Rubens finished his apprenticeship and entered an artists’ guild in 1598, so let’s assume his first documented paintings were completed around the time he was twenty years old. That means he produced an average of more than thirty paintings a year. And that was before the Utrecht chain of art-supply stores was founded. Rubens had to spend a lot of time “hunting and gathering” the materials and supplies needed to make his paints.

A gallon of today’s latex paint weighs a little over eight pounds, and I assume that Rubens’s paints were heavier than that. At those rates, I suppose he shoveled a couple tons of paint onto canvas over his career, a dab at a time. Based on my experience of painting rooms in our house, I know that there were thousands of days when Rubens went home with aching arms and wrists. I read that he died of “complications from gout.” I share the diagnosis of the “disease of kings” and can add that along with his aching carpal tunnel, Rubens suffered a lot of serious pain in his life.

And I have to ask, just how did he do it? How can it be that a 375-year-old painting shimmers with life? Can you buy a tube of “Rubens’s Sunset” or “Rubens’s Nacreous” at a Utrecht store? No? I guess that is the definition of genius.

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Antonio Stradivari lived from 1644 until 1737. He built around 1,100 instruments including 960 violins, of which something like 500 are extant. As a young teenager, he apprenticed with Nicolai Amati and started making instruments under his own name around 1666. He was 93 years old when he died—let’s assume he stopped making violins at age ninety. That works out to about sixteen instruments per year across a sixty-nine year career, or an average of more than one each month. His work must have included traveling from Cremona, the city where he lived and worked, into the forested mountains to acquire materials. Along with his legendary professional career, he had an active personal life with ten children, three of whom worked in his shop.

Like Rubens’s paintings, Stradivari’s violins have stood the test of time, shimmering with life after 300 years. In recent days, we have heard the newest chapter in the dramatic story of a Stradivari violin. The “Ames” Strad was built in 1734, when Stradivari was ninety years old. It was owned by the virtuoso Roman Totenberg who taught at the Longy School of Music in Cambridge, Massachusetts. After a concert there in 1980, the instrument was stolen from Totenberg’s office by Phillips Johnson, an aspiring young violinist. Following Johnson’s death in 2015, his ex-wife and her present boyfriend were cleaning out closets and found the violin. She took it to an appraiser who gave the classic response, “I have good news, and I have bad news.”

The violin was returned to Totenberg’s daughters Amy, Jill, and Nina by the FBI through the office of New York District Attorney, Peet Bharara. Nina Totenberg’s stories about her father’s violin have been broadcast and published by National Public Radio where her voice is well known as NPR’s legal affairs correspondent. Her most recent story was published on October 9. You can read it at https://www.npr.org/2018/10/09/654490918/the-tale-of-the-stolen-totenbe….

In that story, Ms. Totenberg continues by telling of how she and her sisters have chosen to dispose of the instrument. She wrote that they “could sell it for oodles in Asia but would likely never hear it again.” They had placed the instrument in the hands of Rare Violins in New York City, where Ziv Arazi and Bruno Price were restoring it when “an angel” came forward, offering to buy it and place it on loan to deserving students. Eighteen-year-old Nathan Meltzer, a student of Itzhak Perlman and Li Lin at the Juilliard School, is the first to receive use of the instrument on a long-term loan. Nina Totenberg reports that he “already has enough of a career to pay the considerable insurance and maintenance costs.”

According to The New York Times, the “angel” paid between five and ten million dollars to purchase the instrument, which sounds like oodles to me but is a fraction of the record sixteen million paid for a Stradivari violin. An even more rare Strad viola was sold at auction in 2014 for $45,000,000. The Totenbergs chose this path in honor of their father’s devotion to teaching, and in the interest that his beloved instrument would be heard on the world’s stages “long after we’re gone.”

Some people think pipe organs are expensive but consider this: violins weigh between 400 and 500 grams, or something close to one pound which means violins can cost as much as $15 million a pound! In comparison, a three-manual pipe organ with sixty or seventy stops, a solid wood case, and steel frame weighs around 65,000 pounds and costs $1.5 to $2 million which is around $30 per pound. That’s quite a bargain!

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Last Saturday at the Church of the Heavenly Rest, sitting among a throng of colleague organbuilders, listening to the beautiful music and singing those rousing hymns, I was reflecting on the nature of organbuilding. I thought of the math and physics involved in the production and projection of acoustic tone. I thought of the myriad skills required, like woodworking, metalworking, engineering, logistics, rigging, and hoisting. A good organbuilder is well schooled in the history of the instrument including geographical influences, in the flow and volume of air, and the physics of musical tone.

There is a huge amount of pure heavy physical labor involved. That 65,000-pound organ I mentioned includes 65,000 pounds of parts that have to be built, painted, soldered, joined, and carried around the workshop countless times. That is 65,000 pounds of stuff that has to be sorted, wrapped, packaged, and loaded onto trucks, then taken out of the trucks and carried up the steps into the church. Sometimes when relocating a vintage organ, we take it apart, pack it and load it into trucks, unload it into storage, take it from storage to an organbuilder’s workshop, and then move it from the workshop to its final destination. That means lifting, carrying, sorting, and stacking 65,000 pounds of gear three times. That is a lot of cardio training.

Building a twenty-five-foot-tall organ case involves deriving a cutting list from drawings and running thousands of feet of rough lumber through jointer, thickness planer, table saw, and cut-off saw. It means cutting joints, gluing up panels and frames, cutting and mitering moldings, making everything fit together, and hoisting it all into place. Making wood trackers for a big organ is another long shift at the table saw, ripping carefully planed boards into hundreds of two-millimeter strips. Casting the metal for organ pipes means lifting sixty-pound ingots of metal into a melting pot. Be careful not to splash.

In March of 1982, my former wife and I were expecting our first child. In the days leading up to the “due date,” I was drilling holes in the rackboards of an organ. It was not a large organ, fewer than 1,000 pipes, but that was several days of work, changing the bit to a larger size every couple of holes. (Always start with the smallest holes, because if you make a mistake it is easier to make a hole bigger than to make it smaller!) I do not remember if I was making mistakes with drill sizes because I was preoccupied with the idea of becoming a father. Michael was born on a Thursday night, so I had to cancel choir rehearsal. We shipped that organ to Annandale, Virginia, that June, and Michael is now six foot, four inches and a magician with tools and sailboats.

If you are drilling 1,000 rackboard holes in a fifteen-stop organ, you are also drilling 1,000 holes in sliders and 1,000 holes in windchest tables. A big part of the art of organbuilding is knowing where to put the holes.

Many organ companies, including the Organ Clearing House, have heavy schedules of seasonal organ maintenance. We are in the north where the climate changes twice a year. While some organists like to have the organ tuned for Christmas and Easter, because organ tuning is affected by temperature, we like to think of the schedule as winter and summer. It is defined specifically by when the church’s heating system comes into use. If we tune in mid-to-late November, the organ will be ready for the winter season, and around here, Easter is still typically a winter holiday. We tune again in May, and the organ is ready for summer weddings.

I go to about forty organs each season. We arrange the schedule to group neighboring churches. Some organs can be serviced in a couple hours, so we can do three in a day. Most are half-day tunings. This adds up to about three weeks of driving from one church to another, carrying toolboxes into organ lofts, and climbing ladders. Today we have snazzy battery-powered work lights with brilliant LEDs. They are light and compact and have hooks and magnets on them so you get them to stay just where you need the light. But “back in the day,” we had “trouble lights,” incandescent bulbs with metals cages around them powered by heavy yellow cords. It was a trick to keep the cord out of the mixture, and when you were making a difficult repair in a tiny space, there was nothing like the feeling of that hot light scorching the sweaty skin on the inside of the arm.

If that repair involved making a new solder joint, there was nothing quite like that drip of solder on your cheek. I drew laughter from a co-worker when I dubbed a certain move the “Skinner Jerk.” That is when you kneel on a loose screw on a concrete floor, jump up, and hit your head on the torn slot of a bottom-board screw, and pull away leaving a tuft of hair caught in the compression spring. I can hear colleagues chuckling over this because I know we have all done it.

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Why do we go to all that trouble? Why do we go to all that expense, $30 per pound at 65,000 pounds? Why do we tax our bodies and our brains? That question was answered eloquently for me at Steve’s memorial service. There is a mighty organ at Church of the Heavenly Rest, with plenty of power to support lusty singing, and ethereal affects for the most-tender moments. That organ is maintained by Jim Konzelman, a familiar figure in the New York metropolitan area. He was present for the service, and I know he had spent many hours the previous week preparing the organ for Steve’s service. So many of Steve’s friends were there to play it. So many of Steve’s friends were there to listen and to participate.

We do this work because the results move people. I was surely moved last Saturday. It was a special thrill to sing with other organ tuners. It occurred to me that hardly any choir can tune accidentals and leading tones as well as a choir of tuners, there was just something about it.

The memories of a lifetime of hard work have been in mind all week. I know I have shared the story of façade pipes in Cleveland in these pages before. It was the summer of 1977, between my junior and senior years at Oberlin, and my mentor Jan Leek and I joined a crew of Hollanders from Flentrop to install the marvelous three-manual organ at Trinity Cathedral in Cleveland, Ohio. Jan is a first generation Dutchman and was a great friend of the Flentrop firm. The mahogany case was erect, and we were installing the façade pipes. It is a sixteen-foot façade of polished tin, and the pipes are very heavy and require careful handling. I was wearing a harness that could have been used to carry a flagpole in a parade. The toes of those huge pipes sat in the cradle, and as a team we climbed ladders and hoisted from above, guiding the precious and massive pipes into place.

When the day was over and Jan and I were walking down the nave to leave the church, we turned to look at the organ and saw those spangly new pipes reflecting a brilliant blue and red wash of afternoon light coming through the stained-glass windows. I burst into tears.

That’s why we do this.

Making things

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

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

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

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

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

Color my world with a spring in my step.

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

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

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

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

Organ shops

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

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

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

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

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

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

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

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

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

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

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

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

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

Notes

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

Photo:

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

Doo-dads

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

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

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

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

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

A man and his tools

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

• Many sets of drill bits.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

• open-end wrenches;

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

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

• screwdrivers;

• that set of Marples™ chisels;

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

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

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

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

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

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

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

It’s not just an organ shop.

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