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In the wind . . .

John Bishop
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Technology widens the rift.

The other day while running around the house getting ready for work, I heard snips of a story on National Public Radio about the death of Australia’s last veteran of World War I. I missed the man’s name and didn’t hear how old he was, but it’s safe to guess that he was born sometime around 1900. I reflected on the dramatic march of history encompassed by his lifetime, and I recalled a conversation with my grandfather shortly after astronaut Neil Armstrong stepped off a metal ladder onto the surface of the moon. That wise and lovely old man pointed out that his lifetime spanned a comprehensive history of transportation from horse-drawn carts to space travel.

As I write this afternoon, I type my thoughts into a laptop with a twenty-two gigabyte hard drive. I’m no computer historian, but I’m sure that NASA didn’t use a machine as powerful as mine to guide Mr. Armstrong’s route. In fact, I suspect that a lot of the calculating was done with slide rules. My work with the Organ Clearing House involves the management of thousands of photographs so my twenty-gig hard drive is full. I solved that problem by purchasing a sixty-gig supplemental drive. It’s the size of a Band-Aid® box and cost about $150. Navigation involves spherical trigonometry. It’s tricky enough to do those calculations on earth, crossing an ocean for example—it’s exponentially more complicated to navigate between celestial bodies when one is orbiting the other and both are orbiting the sun. How can it be that I need more computing power and memory to manage my organbuilding career than was available for celestial navigation forty years ago?

When President Richard Nixon was defending himself against an impeachment inquiry in the early 1970s, he and those around him were manipulating transcripts of the infamous taped conversations that were being used to implicate him. We read that it took a platoon of secretaries working through the night to retype a transcript in time for a court-appointed submission deadline when a passage was to be deleted in the interest of deceiving the public. This afternoon when I look back on a previous paragraph and have second thoughts all I have to do is highlight and delete. How can it be that I have more stenographic power on my desk than the collective resources of the Nixon White House?

Where are we, anyway?

When I was growing up I loved riding in the car watching the countryside go by. After a childhood and adolescence of looking out the window while your parents did the driving, you’d have a good idea of where you were going when you finally could drive yourself. But now when you shop for a new car you’re surprised to see how many models are supplied with video screens and DVD players. Of course we need those video systems to keep the kids quiet so we can talk on the phone. The logical continuation of this illogical progression is that we can anticipate a generation of new drivers who have no idea where they are going. They’ll have to be taught the meaning of a stop sign or a traffic light. They might not know the way from their home to their school. And they’ve been deprived of thousands of hours of conversation with their parents, siblings, and friends. The good news is that car makers have anticipated this problem. Long before those lost young drivers sit behind the wheel for the first time they’ll be used to satellite navigation. Why strain your eyes looking out the window when you can have a pixilated map on a dashboard screen?

Several years ago my son participated as a crew member competing in a popular annual sailboat race from Cape Cod to Bermuda. There were around a hundred-eighty boats from many different classes so the race officials used a handicap system to level the field, allowing slower boats a mathematical advantage. A further feature of the handicapping system allowed an advantage to those skippers who navigated by the stars without the aid of global positioning satellites and other sophisticated devices. Imagine using a sextant to figure out where you are in mid-ocean when for a few hundred dollars you can have an electronic gizmo that would do it for you. If you’re going to go to all that trouble to know how to do something, shouldn’t you be rewarded for it? (By the way, Mike was in a boat with a sextant!)
In an Op-Ed column in the New York Times of Sunday, October 16, 2005, Pulitzer-prize winning biographer Edmund Morris commented on the recent discovery of the original manuscript of Beethoven’s transcription for piano, four hands of his Grosse Fuge, originally written for string quartet. Mr. Morris began the column by saying that his first reaction to hearing this news was
an aching desire to see it. . . . Beethoven’s manuscripts are revelatory, because he was an intensely physical person who fought his music onto the page, splattering ink, breaking nibs, even ripping the paper in the process. Not for him the serene penmanship of J. S. Bach, whose undulant figurations sway like ship masts over calm seas, or the hasty perfection of Mozart, or the quasi-mathematical constructs of Webern. Their writing is the product of minds already made up.


As he continues, Mr. Morris laments society’s progress away from the authentic process of creating art:
It is already a given that many young architects can’t draw, relying on circuitry to do their imaging for them. . . . Recently my wife and I bought a country house designed by just such an architect. It looked great until we discovered that the main floor sagged in the middle because it lacked the kind of central support that a child, 40 years ago, would have sensed was necessary in the foundation.


Forty years ago, I could have been that child. I credit much of my understanding of load-bearing support, hoisting and rigging, and mechanical advantage to Christmas packages that contained Erector Sets®, Tinker Toys®, Lincoln Logs®, or Legos® just the way I base my knowledge of local geography and my sense of direction on looking out the window of the car when I was child. (Now my wife accuses me of navigating by steeples because I can find my way through unfamiliar neighborhoods using as landmarks the distant steeples of churches where I have worked.) Have you heard about the structural principal of the triangle as a rigid physical form? Assemble a square using four Erector Set® beams of equal length, four bolts, and four nuts. You’ve made a form that you can easily collapse into something like a straight line. Add another piece to form a diagonal across the square. Now it’s two triangles and you can’t collapse it. Simple. (The same grandfather showed me that when I was little.) You don’t need an engineering degree or a computer with a CAD (computer-aided-design) program. You learned it the simple way and you’ll never forget it. Drive past a construction site where there’s a tall crane at work and wonder how it holds itself up. Easy—it’s nothing but a long string of triangles. Arrange your triangles into a succession of three-dimensional forms, and voila: a geodesic dome with thanks to Buckminster Fuller—a simple-to-build roof that can support a load of snow.

They don’t build ’em like they used to.

I know, I know—I sound like an old timer (I really did walk two miles to school every day!). But we who have built our lives around the pipe organ have a unique opportunity to rub shoulders with the good old days. I’ll always appreciate the lessons learned working on a venerable antique organ. While restoring an organ built in 1868 by E. & G. G. Hook, I was particularly impressed by the clarity of the workers’ pencil marks. Those pencils were so sharp that there was no discernable width to the line they left. Mark a mortise on a piece of wood with a pencil you’ve sharpened to a one-molecule point and you’ll certainly cut it just as clean with a chisel. In a modern organ shop, the same oilstone used to sharpen the knife that’s used to sharpen the pencil that’s used to mark the mortise is also used to sharpen the chisel that’s used to cut that mortise. That’s the way it used to be and that’s the way it is!
In fact, they do build them like they used to. Organbuilders commonly celebrate the completion of an organ in the workshop with a party—an “open house.” If you don’t happen to live near an organbuilder, plan ahead when you’re thinking of planning a vacation. Call several organ shops to ask if they have an open house coming up and plan your trip around it. If you’d like some hints, give me a call. You’ll be rewarded not only by seeing a brand-new instrument and meeting other organists and organbuilders, but you’ll certainly be able to get a sense of how ancient honored methods and traditions have been brought into the twenty-first century.

Remember the fundamentals.

When you attend that open house, you might learn the importance of reading the grain of a piece of wood before making it into part of the organ. Look at the end of a piece of wood and you’ll see the pattern we call end-grain. Sometimes you can see the circle of the tree’s rings, sometimes you see a flat pattern where the lines of the grain are parallel with the wide surface of the board, sometimes those lines are perpendicular to the wide side of the board. Draw a cross-section picture representing a tree’s growth rings with concentric circles, draw lines across it that represent boards cut out of the tree, and you’ll be able to figure how a raw tree can be milled to achieve a certain pattern. Why does this matter? Wood warps with the growth rings. In other words, when the end-grain pattern is parallel with the wide side of the board, the board will warp toward the wide side. Consider the keyboards and pallets of an organ with slider chests. If you as the organist could choose, you’d surely prefer to have keyboards warp up-and-down so the individual keys wouldn’t warp into each other and bind, and you’d surely prefer to have the pallets warp side-to-side leaving the gasketed surface flat against the windchest grid avoiding ciphers.

You can choose. Your organbuilder should make the keyboards using wood with the flat grain (often called slab grain). Pallets should be made using wood whose end-grain is perpendicular to the surface of the windchests. Your keyboards won’t stick, and your pallets won’t cipher. Remember the fundamentals.

Those thoughts on end-grain offer a glimpse into the art of making a pipe organ. Organbuilders combine natural and synthesized materials, adapt ancient forms and ideas and combine them with new. They work out the structural requirements of the instrument, computing how its weight is distributed and supported. They fill in the right number of squares with diagonals to make the triangles that keep the instrument’s structure from wobbling or falling. Perhaps their drawings look like Beethoven’s scores, rife with erasures, crossing-out, conflicting ideas. Or do they achieve “undulant figurations” (à la Bach), “quasi-mathematical constructs” (à la Webern) or, God forbid, “hasty perfection” (à la Mozart, whose mind was already made up)?

There’s a big gap between taking the long route and avoiding short cuts—and the right way is somewhere in between. Creating works of art—novels, plays, paintings, statues, musical performances, musical instruments—is strengthened by remembering the fundamentals. All are made possible by the pedagogy, the drudgery, and the excitement of early learning. There’s no substitute for learning the fundamentals. You cannot develop a credible view of the world and your place in it while watching DVDs in the back of the car.

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In the wind . . .

John Bishop

John Bishop is executive director of the Organ Clearing House.

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webJan11p15-16.pdf (647.54 KB)
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The truth about holes
Almost thirty years ago my wife and I were expecting our first child. I was working for organbuilder John Leek in Oberlin, Ohio, and we were in the midst of building an organ for St. Alban’s Episcopal Church in Annandale, Virginia. I was drilling the holes in rackboards—those horizontal boards mounted on windchests that support the pipes about six inches above the toeboards.
It wasn’t a large organ, only eleven stops on the manuals, so including the Mixture, there were about 760 holes to drill. That’s not quite 14 ranks times 56 notes, but some were in the façade, and some others were tubed off the main chests and mounted on the inside walls of the case.
You determine the sizes of the holes using a jig that is a mock-up of a toeboard-rackboard assembly with holes drilled in the rackboard to match all the appropriate drill sizes. You move each pipe among the holes in the jig until you find the right size, then write the drill size on the rackboard by the mark for the pipe hole. That being finished, I had laid out all the marked rackboards on a table near the drill-press and was going through all the boards with each change of the drill-bit. I start with the smallest holes in the remote chance that I might drill one extra hole of a given size. If you make a mistake, it’s easier to drill a hole bigger than smaller!
I suppose I would have been using around 30 different bits for this job, starting with something like 7/32″, graduating by 32nds to one inch, by eighths to two inches, and by quarters to three. I guess it took about a day-and-a-half, and all the while I was expecting that call from home. I was sure it wouldn’t be on Wednesday. It would have to be Thursday, because that would mean I’d have to cancel choir rehearsal, an ice storm was predicted, and the hospital was an hour away in Cleveland. Sure enough, Michael joined us on Thursday afternoon. A couple days later I went back to finish the rackboards. I have no specific recollection, but I bet there were a few mistakes.
If you’d like to know something about this organ, go to <A HREF="http://www.stalbansva.org/">www.stalbansva.org</A&gt;, click on “Ministries,” then click on “Music.” You’ll see photos of the organ and its stoplist.

On with the show
The same number of holes must be drilled in the toeboards, the sliders, and the windchest table in order for the notes to play. That makes about 3,200 holes. But wait, I almost forgot to mention that the toeboards were laminated with interior channeling because the spacing of the slider holes is closer together than that of the pipe holes—so add another 780 holes.
We drill holes in the ends of squares and roller arms to accommodate the tracker action. We drill holes in the keyboards for balance and guide pins. We drill thousands of screw holes to hold the whole thing together. In an electro-pneumatic organ there are rows of holes that serve as pouch wells, pitman wells, housings for primary and secondary valves, and miles of channeling drilled through various windchest components to connect the interior of the pouch wells to the atmosphere, allowing pneumatics to exhaust when actions are activated. Counting on my fingers, I guess that there would be something like 7,000 holes in a ten-stop pitman windchest. Really!
You might say that the art of organbuilding is knowing where to put the holes, and what size each should be.
Drill baby, drill!

Just a little bit
There are hundreds of drill-bits in any organbuilding workshop. There are multi-spur bits that have center points for drilling larger holes. There are Forstner bits that are guided by the outside edge rather than by a center point, handy if you need to “stretch” a hole by cutting another half-moon. There are twist drills with 60º bevels on the points for drilling smaller holes such as screw holes. These are also used to drill holes in metal. There are countersinks that chamfer a screw hole so the flat head of a flat-head screw is flush with the surface of the wood. There are airplane bits, which are twist drills 16 or 18 inches long. I don’t know why they’re called airplane bits. Drilling holes in airplanes wouldn’t require a very long bit.
Any organ shop will sport an impressive rack with rows of bits arranged in order of size. The smallest might be around one-hundredth of an inch, the largest would be something like three inches.

Twist-and-turn
You need a variety of machines to turn those bits. The workbench workhorse is now the rechargeable drill. I have had a long habit of calling the electric hand drill a “drill-motor” much to the annoyance of at least one of my co-workers. In my mind this distinguishes the machine from the bit. You use a drill-motor to turn a drill-bit. I think that if you just say “drill” you could be referring either to the motor or the bit. Let’s be specific. I know I got that habit from someone else, but I don’t remember who. Terence, I didn’t make it up.
We have electric hand drills with half-inch chucks that can handle the larger multi-spur bits, but there is a lot of torque involved in drilling large holes, and if you are bearing down on the thing with your shoulder to cut through the wood you run the risk of getting whacked in the chin by the handle of the drill motor when the bit gets caught in the wood. It’s never actually happened to me but I’ve read about it! (But notice I said “when,” not “if.”)
The workshop workhorse is the drill-press. It’s a stand-up machine with a motor at eye level that’s connected to the arbor with a series of belts. The belts are arranged on stacks of pulleys—you can move the belts to different-sized pulleys to change the speed of the drill. There’s a sheet metal hood over the pulleys to protect the worker. We use slower speeds for drilling through metal—the harder the metal, the slower the speed—and if you’re drilling through a piece of steel, it’s a good idea to have a can of oil with you to lubricate the hole every few seconds. But be careful not to get oil on the surface of any of your wood pieces, as that will foil your attempts to glue pieces of wood together, or to put nice finishes on the wood when the piece is complete.
There’s a spoked handle that you turn to drive the drill-bit into the piece of work. There’s a table which is normally square to the drill-bit, but that can be adjusted if you need to drill a hole at an angle. We stand at the drill press, one hand holding the work firmly against the table, the other working the handle to move the drill-bit into the wood. If you have long hair and you’re not careful, you can get it caught in the pulleys and lose a tuft. If you have loose clothing or, God forbid, a necktie, you can get reeled violently into the machine like a big dull catfish being reeled into a boat.

Careful of blowout
When you’re drilling holes with multi-spur bits, you have to drill from both sides of the wood, or the bit will tear the opposite surface as it goes through the board. It will also tear up the table of the drill-press. So the location of the hole is marked with a smaller bit, say one-eighth, that goes through the board. You drill in a little way with the big bit, then turn the board over and drill from the other side. Doesn’t that double the number of holes you’re drilling?

The saw, the hole-saw, and nothing but the saw
A hole-saw is a specialty tool that’s turned by a drill-motor or drill-press. It’s a circular saw blade with the teeth pointing downward, something like an aggressive cookie-cutter. There’s a smaller twist drill-bit mounted in the middle that guides the center of the hole. They come in sets graduated by the quarter-inch, nestled inside one another like those Russian Babushka dolls. Hole-saws are relatively easy to handle up to six inches in diameter. Bigger than that and they get to be rambunctious. Hole-saws are great for cutting wind holes in reservoirs and windchests. Take a look at this McMaster-Carr page: <http://www.mcmas ter.com/#hole-saw-sets/=9qqoqp>.

Circle cutters
If you need a hole larger than three inches, use a circle cutter (http://www.mcmaster.com/#adjustable-hole-cutters/=9qqq0f). It has a twist drill-bit to center the hole, and a cutter mounted on an adjustable arm. You can set these up to cut holes nearly eight inches in diameter. But be sure to set the drill-press on the slowest speed, and use clamps to hold your work piece to the drill-press table. These tools are pretty scary. They can jam in the track they cut, and the holes often burn during drilling. And if you don’t tighten the set-screw that fastens the adjustable arm, it can get flung across the shop by the motion of the machine.

Oops
What happens if you put a hole in the wrong place? (Never happened to me.) You can glue in a piece of dowel and cut it flush, but the grain will be running in the opposite direction. Better to use a plug-cutter. With this neat tool you can drill into the face of a piece of wood and produce a cross-grained dowel about an inch long. Drill out your mistake with the correct size bit, and glue in your plug. Sand it off and you’ll have a hard time finding it again: <http://www.mcmaster.com/#wood-plug-cutters/=9qqszb&gt;.

The twist
Twist drill bits come in many sizes. I have three basic indexes of twist drill-bits near my drill-press. One goes from one-eighth to one-half an inch, graduated by 64ths. One is an industrial wire-gauge numbered set—the numbers go from 1 (.228″, which is a little less than a quarter-inch) to 80 (.0135″, which is very tiny!). And the third is “letter-gauge” that goes from A (.234″, or .006″ larger than the number 1) to Z (.4130″, or a little smaller than 7/16″).
I have a chart hanging on the wall nearby that shows all three sets graduated by thousands-of-an-inch. If you’re going to drill axle holes in action parts you choose the material you’re going to use for the axle (let’s say it’s .0808″ phosphorous bronze wire), then choose a drill-bit that’s just a little larger. The 3/32″ bit is way too big at .0938″. The #45 bit is .082″ and the #44 bit is .086″. Here the choice would be between the #45 and the #44, so I’d drill one of each and try the wire in the hole. But wait! I have one more trick—a set of metric twist drill-bits graduated by tenths-of-a-millimeter. The 2.2-millimeter bit is .0866″. That’s .0006″ larger than the #44 but I bet it’s too large. The 2.1-millimeter bit is .0827″. That’s only .0019″ larger than the wire—would be a pretty close fit—probably too tight.
If you’d like a glimpse at what these sets of bits look like, go to <http://www.mcmaster.com/#catalog/116/2416/=9qg6xs&gt;. This is page 2416 of the catalogue of McMaster-Carr Industrial Supply Company, an absolute heaven for the serious hardware shopper. The “Combination Set” at the top of the page has the 64ths to 1/2″, numbers 1–60, and 1–13mm graduated by half-millimeters–—total of 114 bits for $286.54. But be reasonable—this is not the perfect Father’s Day gift for every home handyman. A simple set that goes from 1/8″ to 1/2″ graduated by 32nds to 1/4″ and 16ths to 1/2″ will be plenty, available for about twenty bucks from your Home Depot or Lowe’s store. (I prefer the
DeWalt sets.)

Why the fuss?
You might wonder why I would spend so much energy choosing the right drill-bit, and spending so much money to have at hand an appropriate variety of bits from which to choose. (I bet I have more than $5,000 worth of drill-bits.)
A pipe organ is a musical instrument. It’s a work of art. It’s a work of liturgical art. It’s a very special creation. But look inside an organ—any type of organ—and you see machinery. You see thousands of parts and pieces all hung together to make a whole. Some organs look downright industrial inside. That defines a conflict. How can a ten-ton pile of industrial equipment be considered artwork?
The answer is simple. If it’s built to exacting specifications so the sense of the machine melts into the magic of musical response to the fingers and feet of the musician, then it’s artwork. No question, there is such a thing as a pipe organ that’s little more than a machine, but that is not the ideal which our great artist-organbuilders strive to achieve.
If I spend an extra hour making sure that the axle-holes I drill in the set of squares I’m making are exactly the right size, then that keyboard action will feel good to the organists’ fingers, there will be no slop or wobble in the feel of the keys, and the machine I’m making will not impose itself between the musician and the music. (Squares are those bits of tracker action that allow the action to turn corners.)
And remember, if I’m making squares for an organ, I’m making enough of them for each note on the keyboard, and if it’s a larger organ with several keyboards and actions that turn several corners, I might be making 500 squares for the single instrument. While I’m doing that, as long as I think there will be another organ to build, I might as well make a bigger batch—let’s say I’ll spend a week making 2,500 squares. Each has an axle hole, and each has an action hole at the ends of its two arms. That’s 7,500 holes. And those holes are so small that I’ll produce only enough sawdust to fill a coffee can. (I don’t know why I say sawdust when I’m talking about drilling holes, but I’ve never heard anyone say drilldust, and neither has my spellchecker.)

§

The other day I was in a meeting with people from a church who are in the very early stages of dreaming about acquiring a pipe organ. One fellow was really surprised by the cost of organ building—“how can it possibly cost that much to build an organ? You’re going to have to convince me.” I answered him by talking about thousands of person-hours, tons of expensive materials, a workshop equipped with a wide variety of industrial machinery and tools, and collective lifetimes of careful learning and experience forming our staff.
I also told the group that the moment the doubters in a congregation finally really understand why organbuilding is so expensive is the day the new organ is delivered to the church, and the entire sanctuary is filled with exquisitely crafted parts. I’ve been present for the delivery of many new pipe organs, and I’ve often heard the comment, “Now I see why it cost so much.”
As I drove away from that church, my mind took me on this romp about fussing with drill-bits, a reflection on the care, thought, precision, and resourcefulness that I so admire amongst my colleague organbuilders. So I ran back to my hotel room and started to write. I can do the same with lots of other kinds of tools. Want to come see my saws? ■

In the wind . . .

John Bishop

John Bishop is executive director of the Organ Clearing House.

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Measure up
When I was an apprentice working in Oberlin, Ohio, we had a particularly bad winter, with several heavy storms and countless days of difficult driving conditions. As part of our regular work, my mentor Jan Leek and I did a great deal of driving as we serviced organs throughout northeastern Ohio and western Pennsylvania. Jan owned a full-size Dodge van—perfect for our work as it was big enough to carry windchests, big crates of organ pipes, and long enough inside to carry a twelve-foot stepladder with the doors closed, if the top step was rested on the dashboard near the windshield. All those merits aside, it was relatively light for its size and the length of its wheelbase, and it was a simple terror to drive in the snow. There can’t have been another car so anxious to spin around.
Jan started talking about buying a four-wheel-drive vehicle, and one afternoon as we returned from a tuning, he turned into a car dealership and ordered a new Jeep Wagoneer—a large station wagon-shaped model. He wanted it to have a sunroof, but since Jeep didn’t offer one he took the car to a body shop that would install one as an aftermarket option. As we left the shop, Jan said to the guy, “I work with measurements all day—be sure it’s installed square.” It was.
Funny that an exchange like that would stick with me for more than thirty years, but it’s true—organbuilders work and live with measurements all day, every day they’re at work. A lifetime of counting millimeters or sixty-fourths-of-an-inch helps one develop an eye for measurements. You can tell the difference between 19 and 20 millimeters at a glance. A quick look at the head of a bolt tells you that it’s seven-sixteenths and not a half-inch, and you grab the correct wrench without thinking about it. Your fingers tell you that the thickness of a board is three-quarters and not thirteen-sixteenths before your eyes do. And if the sunroof is a quarter-inch out of square, it’ll bug you every time you get in the car.
And with the eye for measuring comes the need for accuracy as you measure. Say you’re making a panel for an organ case. It will have four frame members—top, bottom, and two sides—and a hardwood panel set into dados (grooves) cut into the inside edges. The drawing says that the outside dimensions are 1000mm (one meter) by 500mm (nice even numbers that never happen in real life!). The width of the frame members is 75mm. You need to cut the sides to 1000mm, as that’s the overall length of the panel. But the top and bottom pieces will fit between the two sides, so you subtract the combined width of the two sides from the length of the top and bottom and cut them accordingly: 500mm minus 75mm minus 75mm equals 350mm.
You make a mark on the board at 350mm—but your pencil is dull and your mark is 2mm wide. Not paying attention to the condition of the pencil or the actual placement of the mark, you cut the board on the “near” side of the mark and your piece winds up 4mm too short. The finished panel will be 496mm wide. Oh well, the gap will allow for expansion of the wood in the humid summer. But wait! It’s summer now. In the winter your panel will shrink to 492mm, and the organist will have to stuff a folded bulletin into the gap to keep the panel from rattling each time he plays low AAA# of the Pedal Bourdon (unless it’s raining).
You can see that when you mark a measurement on a piece of wood, you must make a neat clean mark, put it just at the right point according to your ruler, and remember throughout the process on which side of the mark you want to make your cut. If you know your mark is true and the length will be accurate if the saw splits your pencil mark, then split the pencil mark when you cut!
I’ve had the privilege of restoring several organs built by E. & G.G. Hook, and never stop delighting at the precision of the 150-year-old pencil marks on the wood. The boys in that shop on Tremont Street in Boston knew how to sharpen pencils.
Another little tip—use the same ruler throughout the project. As I write, there’s a clean steel ruler on my desk that shows inches with fractions on one edge and millimeters grouped by tens (centimeters) on the other. It’s an English ruler exactly eighteen inches long, and the millimeter side is fudged to make them fit. The last millimeter is 457, and the first millimeter is obviously too big. If I were working in millimeters and alternating between this ruler and another, I’d be getting two versions of my measurements. While the quarter-millimeter might not matter a lot of the time, it will matter a lot sometimes. I have several favorite rulers at my workbench. One is 150mm long (it’s usually in my shirt pocket next to the sharp pencil), another is 500, and another is 1000. I use them for everything and interchange them with impunity because I know I can trust them. With all the advances in the technology of tools I’ve witnessed and enjoyed during my career, I’ve never seen a saw that will cut a piece of wood a little longer. The guy who comes up with that will quickly be wealthy (along with the guy who invents a magnet that will pick up a brass screw!).
My wife Wendy is a literary agent, with a long list of clients who have fascinating specialties. In dinner-table conversations we’ve gone through prize-winning poets, crime on Mt. Everest, multiple personalities, the migration of puffins, flea markets, and teenagers’ brains (!). Her client Walter Lewin is a retired professor from the Massachusetts Institute of Technology, who is famous for his rollicking lectures in the course Physics 8.01, the most famous introductory physics course in the world. On the first page of the introduction to his newly published book, For the Love of Physics: From the End of the Rainbow to the Edge of Time—A Journey Through the Wonders of Physics, Lewin addresses his class: “Now, all important in making measurements, which is always ignored in every college physics book”—he throws his arms wide, fingers spread—“is the uncertainty of measurements . . . Any measurement that you make without knowledge of the uncertainty is meaningless.” I’m impressed that Professor Lewin thinks that inaccuracy is such an important part of the study of physics that it’s just about the first thing mentioned in his book.
The thickness of my pencil lines, my choice of the ruler, and the knowledge about where in the line the saw blade should go are uncertainties of my measuring. If I know the uncertainties, I can limit my margin of error. I do this every time I make a mark on a piece of wood. And by the way, if you’re interested at all in questions like “why is the sky blue,” you’ll love Lewin’s book. And for an added bonus you can find these lectures on YouTube—type his name into the search box and you’ll find a whole library. Lewin is a real showman—part scientist, part eccentric, all great communicator—and his lectures are at once brilliantly informative and riotously humorous.
Now about that panel that will fit into the dados cut in the frame members. Given the outside dimensions and the width of the four frame pieces, the size of the panel will be 850mm x 350mm (if your cutting has been accurate). But don’t forget that you have to make it oversize so it fits into the dado. 7.5mm on each side will do it—that allows for seasonal shrinkage without having the panel fall out of the frame. So to be safe, cut the dados 10mm deep allowing a little space for expansion, and cut the panel to 865mm x 365mm—that’s the space defined by the four-sided frame plus 7.5mm on each side, which is 15mm on each axis. Nothing to it.
Now that you’ve all had this little organbuilding lesson, look at the case of a good-sized organ. There might be 40 or 50 panels. That’s a lot of opportunity for error and enough room for buzzing panels to cover every note of the scale.

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For the last several days I’ve been measuring and recording the scales and dimensions of the pipes of a very large Aeolian-Skinner organ that the Organ Clearing House is preparing to renovate for installation in a new home. I’m standing at a workbench with my most accurate measuring tools while my colleague Joshua Wood roots through the pipe trays to give me C’s and G’s. Josh lays the pipes out for me, I measure the inside and outside diameters, thickness of the metal (which is a derivative of the inside and outside diameters—if outside diameter is 40mm and the metal is 1mm thick, the inside diameter is 38mm. I take both measurements to account for uncertainties.), mouth width, mouth height, toehole diameter, etc. As I finish each pipe, Josh packs them back into the trays. With a rank done, we move the tray and find another one. Now you know why I’m thinking about measurements so much today.
When studying, designing, or making organ pipes, we refer to the mouth-width as a ratio to the circumference, the cut-up as a ratio of the mouth’s height to width, and the scale as a ratio of the pipe’s diameter to its length. If I supply diameter and actual width of the mouth, the voicer can use the Archimedian Constant (commonly known as π - Pi) to determine the mouth-width ratio, and so on, and so forth.
Here’s where I must admit that my knowledge of organ voicing is limited to whatever comes from working generally as an organbuilder, without having any training or experience with voicing. My colleagues who know this art intimately will run circles around my theories, and I welcome their comments. From my inexpert position, I’ll try to give you some insight into why these dimensions are important.
The width of the mouth of an organ pipe means little or nothing if it’s not related to another dimension. Using the width as a ratio to the circumference of a pipe gives us a point of reference. For example, a mouth that’s 40mm wide might be a wide mouth for a two-foot pipe, but it’s a narrow mouth for a four-foot pipe. A two-foot Principal pipe with diameter of 45mm might have a mouth that’s 40mm wide—that’s a mouth-width roughly 2/7 of the circumference, on the wide side for Principal tone. The formula is: diameter (45) times π (3.1416) divided by mouth-width (40). In this case, we get the circumference of 141.372mm. Round it off to 141, divide by 40 (mouth-width), and you get 3.525, which is about 2/7 of 141. Each time I adapt the number to keep things simple, I’m accepting the inaccuracy of my measurements.
The mouths of Flute pipes are usually narrower (in ratio) than those of Principals. Yesterday I measured the pipes of a four-foot Flute, which had a pipe with the same 40mm mouth-width, but the diameter of that pipe was about 55mm. That’s a ratio of a little less than 1/4. The difference between a 2/7 mouth and a 1/4 (2/8) mouth tells the voicer a lot about how the pipe will sound.
And remember, those diameters are a function of the scale, the ratio of the diameter to the length. My two example pipes with the same mouth width are very different in pitch. The Principal pipe (45mm in diameter) speaks middle C of an eight-foot stop, while the Flute with the 40mm mouth speaks A# above middle C of an eight-foot.

§

You can imagine that the accuracy of all these measurements is very important to the tone of an organ. The tonal director creates a chart of dimensions for the pipes of an organ, including all these various dimensions for every pipe, plus the theoretical length of each pipe, the desired height of the pipe’s foot, etc. The pipemaker receives the chart and starts cutting metal. Let’s go back to our two-foot Principal pipe. Diameter is 45mm. Speaking length is two feet, which is about 610mm. Let’s say the height of the foot is 200mm. The pipemaker needs three pieces of metal—a rectangle that rolls up to become the resonator, a pie-shaped piece that rolls up into a cone to make the foot, and a circle for the languid.
For the resonator, multiply the diameter by π: 45 x 3.1416 = 141.37mm (this time I’m rounding it to the hundredth)—that’s the circumference of the pipe, so it’s the width of the pipemaker’s rectangle. Cut the rectangle circumference-wide by speaking-length-long: 141.37 x 610.
For the foot, use the same circumference and the height of the foot for the dimensions of the piece of pie: 141.37mm x 200.
Roll up the rectangle to make a tube that’s 45mm in diameter by 610 long, and solder the seam.
Roll up the piece of pie to make a cone that’s 45mm in diameter at the top and 200mm long, and solder the seam.
Cut a circle that’s 45mm in diameter and solder it to the top of the cone, then solder the tube to the whole thing. (I will not discuss how to cut the mouth or form the toehole.)
But Professor Lewin’s adage reminds us that no pipemaker is ever going to be able to cut those pieces of metal exactly 141.37mm wide. That’s the number I got from my calculator after rounding tens-of-thousandths of a millimeter down to hundredths. You have to understand the uncertainty of your measurements to get any work done.

§

As I take the measurements of these thousands of organ pipes, I record them on charts we call scale sheets—one sheet for each rank. I reflect on how important it is to the success of the organ that this information be accurate. I’m using a digital caliper—a neat tool with a sliding scale that measures either inside or outside dimensions. The LED readout gives me the dimensions in whatever form I want—I can choose scales that give inches-to-the-thousandth, inches-to-the-sixty-fourth, or millimeters-to-the-hundredth. I’m using the millimeter scale, rounding hundredths of a millimeter up to the nearest tenth. As good as my colleagues are and as accurately as they might work, they’re not going to discern the difference between a mouth that’s 45.63mm wide from one that’s 45.6mm.
And as accurately as I try to take and record these measurements, what I’m measuring is hand made. I might notice that the mouth of a Principal pipe is 16.6mm high on one end and 16.8mm high on the other. A difference of .2mm can’t change the sound of the pipe that much—so I’ll record it as 16.7. I know the uncertainties of my measurements. I adapt each measurement at least twice (rounding to the nearest tenth and adapting for uneven mouth-height) in order to ensure its accuracy. Yikes!

§

Earlier I mentioned how people who work with measurements all the time develop a knack for judging them. I’ve been tuning organs for more than 35 years, counting my way up tens of thousands of ranks of pipes, listening to and correcting the pitches, all the time registering the length of the pipes subconsciously. With all that history recorded, if I’m in an organ and my co-worker plays a note, I can reach for the correct pipe by associating the pitch with the length of the pipe.
π (pi) is a magical number—that Archimedes ever stumbled on that number as the key to calculating the dimensions of a circle is one of the great achievements of the human race. How can it be possibly be true that πd is the circumference of a circle while πr2 is the area? Here’s another neat equation. A perfect cone is one whose diameter is equal to its height. The volume of a perfect cone is exactly half that of a sphere with the same diameter. How did we ever figure that one?
There are no craftsmen in any trade who understand π better than the organ-pipemaker. When you visit a pipe shop, you might see a stack of graduated metal rectangles destined to be the resonators of a rank of pipes. The pipemaker knows π as instinctively as I can tell that the first millimeter on my ruler is too big. Imagine looking at a tennis ball and guessing its circumference!

§

When you’re buying measuring tools, you must pay attention to accuracy. Choose an accurate ruler by comparing three or four of them against each other and deciding which one is most accurate. Choose an accurate level by comparing three or four of them. You’ll be surprised how often two levels disagree. Just as mathematics gives us the surety of π, so physics gives us the surety of level. There is only one true level!
I’ve been showing off all morning about how great I am with measurements in theory and practice, so I’ll bust it all up with another story about van windshields. I left the shop to drive to the lumberyard to pick up a few long boards of clear yellow pine. They had beautiful rough-cut boards around thirteen feet long, eight and ten inches wide, and two inches thick. Each board was pretty heavy, and as they were only roughly planed, it was easy to get splinters from them. I put the first one in the car, resting the front end on the dashboard right against the windshield. Perfect—the door closed fine, let’s get another. I slid the second one up on the first, right through the windshield. Good eye! 

In the wind . . .

John Bishop

John Bishop is executive director of the Organ Clearing House.

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Shiny side up
The work of the Organ Clearing House involves trucks. Lots of trucks. We rent trucks when we are working on projects small enough to fit into a single truck body. And we have a trucking company in Nevada that we call when we need a semi-trailer or a little fleet of semi-trailers. After many years of jumping around from one company to another, it was a relief to begin working consistently with a single firm that could meet most of our needs.
When we are dismantling an organ, loading day is heavy work. A crew runs in and out of a church building all day long carrying heavy parts down stairs and fitting them into a truck like a giant Tetris® game. When the truck is full there’s often a moment when the crew and truck driver “shoot the breeze” for a few minutes before the load hits the road. We’ve heard a few doozies. One driver mentioned that it was a good thing we weren’t sending him to Canada because he had been convicted for smuggling firearms and wasn’t allowed to drive there anymore. We had just loaded an Aeolian-Skinner organ into his trailer.
Sometimes it’s pearls of wisdom: “You can drive down that hill too slow as many times as you want. You can only drive down it too fast once.”
And the friendly greeting as he puts it in gear and lets out the clutch, “keep the shiny side up!” Good advice, especially with my organ in the back!

Skootch
In 1979 I was part of a crew installing a new European organ in Cleveland. (You historians can route out which organ that was . . .) The church’s sexton, a fifty-ish German man, was involved in setting up the scaffolding, and I as “the young guy” was up there with him. As we were putting up the last scaffold frame we ran into the pitch of the ceiling. “Hold this,” he said, handing me the scaffold frame. I was standing on a plank. He pushed against the ceiling with his hands, gave the scaffold tower a kick with both feet, and the whole thing jumped a couple inches toward the center of the room. We were up high enough to be able to put a bridge from the top of the tower across the top of the organ to another tower. It was a three-manual free-standing organ in a classic organ loft with a spiral stairway. Must have been 50 feet. After his kick the tower didn’t stop making noise for several seconds, and because I was holding that frame I couldn’t steady myself. Nothing bad happened, but as I reflect on that moment, especially watching our crews set up massive towers of scaffolding today, I can hardly believe the risk that guy exposed me to without asking. I would have said no.
In another Cleveland church my boss and I witnessed a near disaster. We walked through the nave heading for the rear gallery where we were finishing renovation of the antiphonal organ. The pews were divided into three sections across the room, so there were in effect two center aisles and no side aisles. The walls featured unusually large stained-glass windows. A couple guys from the church’s maintenance staff were changing light bulbs in the chandeliers, using the kind of scaffolding that’s made of two-inch aluminum tubes and has a two-by-six-foot footprint. They were four sections high, and had the outriggers (stabilizers) pointing up the aisles the “long way,” rather than between the pews. From inside the organ chamber we heard “that” noise and ran down the stairs to find the tower at a 45-degree angle, the bottom of the tower still in the aisle, and Mr. Lightbulb on top with his foot on the wall next to a window. A couple inches to the right and he would have gone through the glass and fallen a long way to the lawn. Telling him to hang on, we yanked the tower straight again, and I had to go up to help the guy down.
What kind of maintenance supervisor would let that happen? Oh yeah, in the first story he was the guy on top of the tower with the big feet.

Those little voices
That Cleveland area organbuilder I was working with is Jan Leek of Oberlin, Ohio. I was privileged to work in his shop part time when I was a student, and then full-time for about five years after I graduated. He had learned the trade in Holland in what could best be described as an old-world apprenticeship, and as he taught me how to handle tools and operate machinery, he had a way of saying, “listen for those little voices.” If the little voice in your head says, “you’re going to cut your finger with that chisel if you do that once more,” the little voice is right. It’s a great image, and I am sure that his description taught me to conjure up those voices. I can still hear them. “The paint is going to drip on the carpet.” “The keyboard is going to fall on the floor.” “Your finger will touch that saw blade.”
The apprentice doesn’t hear the voices. The journeyman hears them and doesn’t listen. The master hears them and does listen.
An open quart can of contact cement is sitting on the chancel carpet next to the organ console. Of course it’s going to get knocked over when you stand up. The price of the glue, $4.79. The price of the carpet, $47,500.
A row of tin façade pipes is standing against the workshop wall. A worker is using a five-pound hammer to break up the crates that the pipes came in. The head flies off the hammer and dents one of the pipes, and they all fall over, one at a time in slow motion like 15-foot-tall tin dominos and there’s nothing anyone can do.
Cheery, isn’t it?
This subject is on my mind for several reasons. One is that I’ve spent the last couple days negotiating the rental of a huge amount of scaffolding and rigging equipment for a large project we will start next week, so I’ve been talking with salesmen about weight and height limits and what accessories are necessary to ensure safety. Another reason is that a locally owned small manufacturing company near us suffered a catastrophic fire last week. And as we work with scaffolding companies in New York we hear stories about the construction industry, especially relating to recent serious accidents involving cranes used in the construction of high-rise buildings.
I love the image of the organbuilder at a wooden workbench, a window open next to him providing a gentle breeze, a sharp plane in his hands, and the sweet smell of fresh wood wafting off the workpiece as the shavings curl from the blade of the plane. Or that of the voicer sitting in seclusion with beautiful new pipes in front of him coming to life under his ministrations.
But think of that majestic organ case in the rear gallery with an ornate monumental crown on the top of the center tower, covered with moldings, carvings, and gilding, and pushed up against the ceiling. Uplifting, isn’t it? It might be eight feet long, six feet wide, and three feet tall. It might weigh 500 pounds, and someone had to put it there. Making it is one thing. Getting it 50 feet off the floor and placed on those 20-foot legs that hold it up is another thing altogether. Uplifting, all right.
Organbuilders have a variety of skills. We work with wood, metal, and leather. We work with electricity and solid-state circuitry. We have acute musical ears for discerning minute differences in pipe speech and for setting temperaments. And we must be material handlers—that specialization of moving heavy things around safely.
To put that tower crown in place you need scaffolding, hoisting equipment, and safety gear to keep you from falling. How high up do you need to be before you need that gear? Easy. Ask yourself how far you’re willing to fall. Twenty feet? Thirty feet? Four years ago the Organ Clearing House dismantled the huge Möller organ in the Philadelphia Civic Center. (That organ is now under renovation in the new workshop of the American Organ Institute at the University of Oklahoma.) The organ chamber was above the ceiling, 125 feet above the floor. The demolition company (the building was to be torn down) cut a hole in the floor of the blower room big enough for the organ parts to pass through. And we were left standing on the edge of an abyss. We used full-body harnesses and retractable life lines. If you fell you’d drop about six feet and the ratchet-action of the retractable would stop you, something like the seatbelts in your car. And there you are, hanging 120 feet up.

Away aloft
A sailor hollers “Away aloft” as the halyard hoists the sail up the mast. The rigger might do the same. He ties a line around the load, hooks it to the line from the winch, and up it goes. It’s important to choose the right type of line—you don’t want chanciness caused by a line that stretches, for example. But what really matters is the knots you use. Some knots are meant to slip. Some are meant to be permanent. A favorite is the bowline, which cannot untie, but also cannot pull so tight that it cannot be undone. It was developed by early sailors to tie a ship to a dock or mooring. Think of a large sailing vessel, bow tied to a mooring, bouncing on the waves and pulled by the wind for weeks. There’s a terrific amount of force on that knot. But you give the top of the knot a push sideways and it can be taken apart easily. Beginning sailors are taught how to tie the bowline both left- and right-handed, blindfolded. I once had to tie a bowline while diving under a boat in order to repair a centerboard control.
Different knots are intended for different purposes.
A half-hitch is a great knot for securing something temporarily, but it looks a lot like a slip knot. If you don’t know the difference you might tie a slip knot by mistake. How will that work when the weight of a windchest shifts while being hoisted into the organ?
If your skill set doesn’t include three or four good reliable knots, I recommend you learn them. There are neat books for this purpose, predictably available from boating-supply companies. Some come with little lengths of line so you can practice in the comfort of your home.
When hoisting heavy parts you can also use nylon webbing. It’s available in neat pre-cut lengths with loops on each end for easy tying. The webbing is easy on the corners of the piece you’re lifting, and it’s very strong. A one-inch wide web is rated for 2,000 pounds in vertical lift. But keep a good eye on its condition. Recently there was an eerie photo in the New York Times in the aftermath of the collapse of a construction crane. It showed a piece of torn webbing dangling from a hook. That photo prompted us to purchase new webbing for our next rigging job!
In the nineteenth century, the great Boston organbuilding firm of E. & G.G. Hook suffered two serious fires, both of which destroyed their workshops. I know of two North American organbuilders who have had bad fires in the last decade. Neither was caused by carelessness; in fact, one was caused by lightning. I thought about those two colleague firms working to rebuild their companies when we heard of a terrible fire at a boatyard near us. Washburn & Doughty is a family-owned company with about a hundred employees that builds heavy commercial vessels like tugboats, fireboats, and ferryboats. It’s quite a spectacle to see a hundred-foot tugboat under construction in a small village. And a mighty amount of steel goes into the building of such a boat. On Friday, July 11, sparks from a cutting torch ignited a fire that destroyed the building. It was routine work for a place like that, and newspaper stories told that the fire was officially accidental. They were able to save a hundred-foot tug that had been launched and was being completed at the dock—they cast it adrift! But two others that were still in the buildings were lost and 65 employees were laid off temporarily while the owners work out how to rebuild.
Ten years ago I was restoring an organ built by E. & G.G. Hook with lots of help from volunteers from the parish. We were refinishing the walnut case, and I mentioned the fire hazard of rags that were soaked with linseed oil. They must be spread out to dry. If they’re left in a heap they will spontaneously combust. One of the volunteers took a pile of the rags home and put them in a bucket in the middle of his backyard. He told us later that it had only taken about ten minutes before the bucket was full of fire!
This is a pretty gloomy subject. But I write encouraging my colleagues to look around their workplaces with a critical eye toward safety. Be sure you have the proper gear for lifting and moving the things you’re working on. Store your paints and finishes in a fire-proof cabinet. Eliminate the possibility of sparks finding a pile of sawdust and spread out those oily rags. Encourage your workers to use safety equipment. Safety glasses may look nerdy, but it’s not cool to lose an eye!
Get your hands on a good industrial supply catalogue—I have those from Grainger and McMaster-Carr on my desk. Go to the “safety” pages and leaf through. You’ll see lots of things that protect against stuff you haven’t imagined could happen! Organbuilders are precious. Let’s keep them all in good health.

In the wind . . .

John Bishop

John Bishop is executive director of the Organ Clearing House

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A material world
It happens to me all the time. A word or phrase comes up in conversation and a song pops into my head. I can’t help it, and I’m often stuck with that song for days and days. The insipid nature of some of the songs startles me—how can I justify the use of my Random Access Memory on such drivel?

Five passengers set sail that day…
polished up the handle of the big front door…
no gale that blew dismayed her crew…
the soda water fountain…
many a mile to go that night before he reached the town-oh, the town-oh, the town-oh…

And let’s not forget the jolly swagman, the girl named Fred, the mule named Sal, and the glorious, sonorous, stentorian Pirate King. (Dear readers, if you know all of these songs, let me know—honor system—and I’ll send you an autographed manuscript of this column.)
We are in the last few weeks of a busy and exciting organ installation. I’m spending a lot of time with supply catalogues, shepherding the flow of materials to the jobsite, trying to keep ahead of the energetic crew as we navigate the final glide-path. (The job is in New York City, and as I come and go, I drive along Manhattan’s western shore on the Henry Hudson Parkway. Speaking of free association, “glide-path” makes me think of Captain Sullenberger’s heroic goose-inspired glide-path over the George Washington Bridge, landing a US Airways jet on those choppy waters.)
But it’s the materials I’m thinking about these days, and I’m stuck with material girl… So sings the ubiquitous and peripatetic Madonna in a song I don’t know. The fact that I don’t know the song doesn’t stop it from circling menacingly between my ears. Material Girl must be second only to Michael Jackson’s Bad in songs in which the highest proportion of the lyrics is the actual title. (You can find the complete words of both at www.azlyrics.com.) I spent $1.29 to download Material Girl from the lyrics is the actual title. (You can find the complete words of both at www.ilike.com as part of my research preparing for this column. (I’ve filed the e-mail receipt for tax purposes!)
My catalogues each have more than 3,000 pages and the consistency of bellows weights. They offer everything from sponges to forklifts, from welders to furniture polish, from pulleys to lubricants to fasteners to shelving to eyewash stations. A list gets shouted down from the organ loft, and a rattles-when-you-shake-it box arrives the next day.
As I unpack the boxes, I reflect on the huge variety of stuff that goes into a pipe organ. It’s part of what’s wonderful about the instrument. We use geological materials (metals and lubricants), vegetable materials (wood), animal materials (ivory, bone, leather, and glue), chemical materials (glues, solvents, finishes)—and I think most organ builders have intimate and personal relationships with many of them.

From the forest
Most organbuilding workshops include plenty of woodworking equipment. The overwhelming smells come from wood—an experienced woodworker can tell by the smell what variety of wood was milled last. It’s impossible to mix up the smell of white oak (burning toast) with that of cedar or spruce (grandmother’s closet). And the working characteristics of various woods are as different as their smells.
White oak is very popular among organbuilders. It can be milled to produce myriad grain patterns, it has great structural qualities, and it takes finishes beautifully. But it’s a difficult material to work with. In 1374 Geoffrey Chaucer wrote in Troilus and Criseyde, “as an ook cometh of a litel spyr [sapling].” We now say, “mighty oaks from little acorns grow,” referring to great things coming from small beginnings. The mighty oak tree is a symbol of strength and stability and of the witness of many passing generations. How many memoirs or novels include the enduring oak tree as the observer, commentator, and guardian of generations of family members?
There was a magnificent and massive oak tree in the yard of my great-grandmother’s house that was known as the “roller-skate tree” by generations of my family. It was so bulky and heavy that several of the major lower limbs had settled to rest on the ground—the ultimate climbing tree for kids, as you could simply walk from the grass to a great height. Some imaginative arborist conceived of building heavy iron-wheeled skids under those limbs so the natural motion of the tree would not harm them as they dragged on the ground.
As the white oak tree is such a massive presence, so it yields its beauty reluctantly. The rough-cut lumber is uncomfortable to handle. It’s heavy—the weight-per-board-foot is higher than most other woods. When the truck arrives from the lumberyard, you’re faced with an hour of heavy and prickly work. And when the mighty tree is felled and milled, the apparent inherent stability transforms into a wild release of tension. As the wood passes through the saw it twists and turns, scorching itself against the spinning blade, and producing the characteristic smell. (By the way, a French government website claims that master Parisian organbuilder Aristide Cavaillé-Coll was the inventor of the circular saw.)
As you look at a standing tree, you can tell a great deal about the wood inside. If the bark shows straight, even, perpendicular lines, you can assume that there’s plenty of nice, straight lumber in there. If the bark is twisted, spiraling around the tree, you know you’re going to be fighting for each useful board.
Red oak is a poor substitute for white oak. The grain patterns are not as attractive, and red oak doesn’t take finishes as well. And it’s not as strong. Cut a piece of red oak a half-inch square and four inches long. Put it in your mouth and blow through it into a glass of water. You can blow bubbles—there are longitudinal capillaries in the wood that deny it the structural strength of its mighty cousin. Try the same experiment with white oak and the sharp edges will cut your lips.
White oak saves its final insult: splinters. The hardness of the wood combines with that tendency to move to produce angry splinters. And like the woods from tropical rainforests whose survival depends on producing gallons of insecticide in the form of sap, there’s a chemical content to a piece of white oak that fosters festering—the wounds from the splinters easily get infected. So a contract for a new organ with a case made of white oak should include a supply of aloe-enriched hand lotion.
The opposite end of the hardwood spectrum is basswood. It’s from the genus Tilia and is also referred to as Linden, the source of Franz Schubert’s song, Der Lindenbaum. It’s a large deciduous tree, as tall as a hundred feet, with leaves as big as eight inches across. And the wood is like butter. It smells sweet coming through the saw, it is easy to mill straight, and once it’s straight it stays there. It’s ideal for making keyboards, because keyboards are about the last part of an organ where we can tolerate warpage. And it’s ideal for carvings, statues, and pipe shades. A sharp tool coaxes even and smooth shavings—you can’t call them chips. It reminds me of the butter molded into little pineapples in trying-to-be-fancy restaurants.
With all the pleasant qualities of basswood, it’s not very strong—no good for structural pieces—and it’s so soft that if you look at it wrong there will be a ding in the surface. While it looks beautiful unfinished, it does not have the attractive grain patterns we look for when we use clear finishes like stain, lacquer, or varnish. On the other hand, it takes paint and gold leaf very well indeed.
I place poplar right between white oak and basswood. It’s strong, relatively hard, mills and sands easily, and smells good. Its grain is not pretty enough to recommend it for use as casework with clear finish, and although poplar is essentially a white wood, it has broad swatches of dark olive-green heartwood. But all its other qualities make it ideal for use building windchests and other components, including painted cases.

From the farmyard
While woodworking is common to many arts and crafts besides organbuilding, leather (at least in any large volume) is more specific to our field. Besides its industrial uses (shoes, clothing, and car seats), leather is used only in small quantities. So, while there are plenty of skilled woodworkers producing furniture and household or office appointments like cabinets and bookshelves, organbuilders stand pretty much alone as large-scale consumers of leather. And those industrial users don’t care much about how long the leather will last. After all, except for the decades-old and beloved leather flight jacket, most of us don’t expect shoes, clothes, or car seats to last more than five or ten years.
Ten years would be a disastrously short lifetime for organ leather, and organbuilders have made effective and concerted efforts to ensure a good supply of leather, tanned according to ancient methods, that will have a long lifetime.
A busy organ shop routinely stocks the tanned hides of cows, horses, goats, and sheep. Cowhide can be produced with a hard slick finish (useful for action bearing points and rib belts on reservoirs) or as soft and supple material for small pneumatics and reservoir gussets (the flexible corner pieces). We also often use goatskin for those gussets. I think goatskin is tougher than cowhide, perhaps an opinion reflecting my comparison of scrappy pugnacious goats and relatively docile cows. Goatskin is supple even when it’s very thick, which makes it ideal for applications requiring plenty of strength and flexibility at the same time.
Horsehide is very strong, but it’s spongy and not supple at all, so its principal use is for gaskets between joints that we expect to be opened for maintenance of an organ. Cutting it into strips and punching out the screw holes prepares it for making gaskets for windchest bungs, removable bottom boards, and reservoir top panels. It’s a good idea to apply a light coating of baby powder or light grease (like Vaseline) to the leather before screwing down the panel to keep it from absorbing oils and resins from the wood, which act as unwelcome glue.
I use more sheepskin than anything else. Our supplier is equipped to plane it to various thicknesses, a process that produces splits as “useful waste.” The raw skin might be a tenth of an inch thick, and we might want leather for pouches and small pneumatics to be one or two hundredths of an inch thick. That leaves us with leather eight or nine hundredths thick, fuzzy on both sides, relatively inexpensive because it’s technically waste, and useful for plenty of things like light gaskets and stoppers of wooden pipes.
As I cut the hides of any of these creatures into organ parts, I’m aware of the animal’s anatomy. When a hide is laid flat on a workbench, you clearly see the neck and legs of the animal, and to make good reliable pneumatics you need to be careful of the natural stretching of the armpits, the belly, and the rump—those places where our skin grows in tight curves and stretches every time we move. When I cut long strips, I cut parallel to the spine to ensure relatively even thickness through the piece. If you cut a piece from belly-edge to belly-edge, it will go from thin to thick to thin again.
When releathering reservoirs, we cut miles of strips of leather or laminated rubber cloth that are around an inch-and-a-half wide. I remember keeping a dedicated straight piece of wood as a cutting surface and a long wooden straightedge as a rule for cutting these strips. I sharpened and honed my favorite knife as though I meant to shave with it. With that set-up, it took plenty of skill and care to produce straight pieces of material. The knife wanted to follow the grain of the wood, and after a few cuts my cutting board was scored, providing more opportunities for my knife to stray. Today, we have rubbery-plastic cutting surfaces, plastic and aluminum straightedges marked in inches or centimeters, and laser-sharpened rotary knives with retractable blades. With proper care, the cutting surface can be maintained blemish-free indefinitely. The knife blades are replaceable, and it’s easy to cut hundreds of near-perfect strips. All this special gear is available in fabric stores. I’m usually the only man in the store when I go in to buy replacement blades. I have to navigate aisles of unfamiliar stuff essential for quilting, sewing, decorating, scrapbooking (an activity described by a verb that can’t be more than a few years old), and countless other arts and crafts activities.
A recent side effect of this quest was my discovery of monster pipe-cleaners of every size and description, up to two feet long and an inch in diameter, perfect for stopping off pipes as I tune mixtures. Between those and the fantastic laser-sharpened cutting tools, I can’t imagine how I ever did organbuilding without fabric stores.
We’ve done forest and field—someday soon we’ll talk about mines and quarries. As the technology of tools develops, we are able to work with an ever-wider variety of metals. We’re used to the tin-lead alloys we use to make most of our organ pipes, but we find more steel and aluminum used for structural elements, action parts, even casework decoration. All the skills required to work this wide range of materials complement those skills related to the organ’s music—voicing, tuning, acoustic planning—and the planning of the projects in the first place—architecture, and yes, politics. Now there’s a subject for another day. 

In the wind . . .

John Bishop

John Bishop is executive director of the Organ Clearing House.

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User Interface
In his book Violin Dreams (Houghton Mifflin Company, 2006), Arnold Steinhardt, first violinist of the Guarneri String Quartet, wrote about the special relationship a violinist has with his instrument:

When I hold the violin, my left arm stretches lovingly around its neck, my right hand draws the bow across the strings like a caress, and the violin itself is tucked under my chin, a place halfway between my brain and my beating heart.
(Regular readers here will no doubt recognize this quote, as I cited it in the July 2007 edition of this column.)
This is a beautiful image of an artist inseparably entwined with his instrument. Any thoughtful and caring musician would wish to have that kind of relationship. But Mr. Steinhardt doesn’t want to share his thrall. He continues,

    Instruments that are played at arm’s length—the piano, the bassoon, the timpani—have a certain reserve built into the relationship. Touch me, hold me if you must, but don’t get too close, they seem to say.

As I pointed out last July, the bassoonist puts the instrument in his mouth. You don’t get more personal than that. While at first read Mr. Steinhardt’s affair with his instrument is beguiling, when I think about it a little, it takes on an elitist sense that is less attractive. I’ve never been a fan of claims that one instrument is more difficult to play than another, or that one is in any sense better than another. While it’s okay for a musician to feel a little chauvinism, each instrument has its place in the rainbow of musical sound, and each has technical challenges for the player to overcome if there is to be true music-making, true art, unfettered by physical limitations.
A timpanist has just as personal a relationship with his instrument as the violinist. The orchestral timpanist caresses the skin of his instrument, puts his ear to it, fiddles with the screws that adjust the pressure of the head so the sound will be perfect when he raises its thunder at the behest of the conductor. A modern orchestral hall is likely to include a special work station for the timpanist with equipment for soaking and preparing the skins, analogous to the “reed room” reserved for those who play and fiddle with the instruments with single and double reeds.
Besides the range of technical challenges facing musicians, there are also intellectual and spiritual challenges. We get used to an instrument, learning its strengths and weaknesses, learning how to make it project best to the listeners, learning how to mold it around the music we are playing. Organists must not only master the instrument, but also the relationship of the instrument to the room. The pipe organ is a spatial instrument, one that relies on its room for resonance and projection, as well as physical beauty. And the keyboards are the connection between the instrument and the player.
User interface is a phrase recently added to our lexicon. We never thought of the steering wheel of a car as a user interface, or the tiller of a boat, the handle of a shovel, or the knobs of a radio. But as soon as computers became everyday devices, user interfaces became ubiquitous.
Our keyboards and pedalboards are the user interfaces of the organ.
I’ve made thousands of service calls in 35 years of caring for organs, and I’ve learned to notice a lot about organ consoles—especially as they reflect the habits and preferences of the local organists. Many are obvious. In churches where I’ve cared for organs for many years, I know what kind of candy or cough drops the organist prefers. Some have remarkably consistent habits over decades, the sounds echoing endlessly over those hallowed (cherry) Halls. The organist who is particular about his fingernails keeps a nail clipper next to the keyboards. Some organists are paper clip junkies—the hymnals are loaded with them, and the floor under the pedalboard is littered with them. When such an organist calls to report that two adjacent keys are sticking, I know instantly that there’s a paper clip caught between them. One organist I knew actively hated paper clips and was abusive in his comments about people who rely on them. “They make such a mess of the hymnal.”
I know which organists put sugar in their coffee—it’s unmistakable in the spills on the pedal keys, spills that are often the cause of dead notes in the pedals as the sugar retains dust that fouls the contacts.
But some of the local organists’ habits and preferences are subtler. I notice that many organists have what I call a “home key.” When sitting down to try a new instrument, they play five-note scales up and down or chords in their home key. If that organist has played on the same instrument for many years, you can see signs of the home key in the way the console is worn. That home key is usually C major. But one organist I know is focused on G, a fact made obvious by the wear of the pedal keys.
It happens that many of my favorite pieces are in E-flat and B-flat major and in F minor. Does that mean that the tonic, dominant, and sub-dominant notes of those keys are more worn on instruments I play frequently? Notice the notes that are common between those keys. I suppose I’m inclined to play the tonic and dominant notes with more élan—and I suppose that end-of-the-piece flourish wears the notes more than an everyday scale.
It’s only the most sophisticated and innovative organists who wear the top eight notes of the pedalboard as much as the bottom eight.
The Organ Clearing House is working on the relocation of a 90-year-old Casavant organ, and yesterday I took the manual keyboards to the workshop of a colleague who specializes in renovating and restoring keyboards. He produces much of the cow bone that is used in keyboards around the world, obtaining animal “quarters” from slaughterhouses, boiling and bleaching the bones, and milling them into eighth-inch-thick blanks to be turned into key surfaces. He sells some of the finished bone to those who make keyboards, and uses the rest of it in his own restoration projects. His workmanship is much sought after. Keyboards are pretty much all he does. There are keyboards everywhere in his shop, and the ambient smell is reminiscent of the dentist drilling out a cavity in your tooth.
So we talked about keyboards. He made interesting comments about how keyboards wear, mentioning as an example that the accompaniment manual on a theatre organ is likely to be especially worn in the tenor octave. We talked about pitfalls of keyboard construction—where a sharp edge or corner is liable to injure a player’s fingers. (Once playing on a new organ, I cut a finger seriously enough that I had to leave the console to find a bandage in the middle of a service.) We talked about how different materials used for the playing surfaces absorb moisture more easily. An organist with naturally oily skin will be less comfortable playing on plastic keys than on bone or ivory. And the keyboards played by an organist with naturally oily skin get dirtier faster. This is not a criticism, just an observation.
There is huge variety in the design, size, style, and feel of pipe organ keyboards. As a student at Oberlin, I often practiced on a tiny three-stop “practice machine” built by John Brombaugh. The keyboards were smaller than what I was otherwise used to. The distance between the front of the naturals and the front of the sharps seemed impossibly tiny. The edges and corners of both naturals and sharps were keen—not so as to be dangerous, but so as to be obviously different from other styles. The tracker action was precise—you might say horribly precise—the “pluck” of the keys was both distinct and delicate. While intellectually I know that “pluck” is caused by resistance of the wind pressure against the pallet with the unmistakable little “whoosh” you feel when the air rushes around the released pallet and essentially blows it open, as I play I feel it as a physical click. These characteristics of that practice organ provided a terrific pedagogic medium. The keyboards demanded exact accuracy. If you were in the least way unintentional, the notes came in clusters instead of chords and scales. If you could play a passage musically and accurately (are the two separable?) on that instrument, you could play it anywhere. Reminds me of the legend of Abraham Lincoln practicing oration with pebbles in mouth.
That’s a wonderful way for a keyboard to feel, and wildly different from the keyboards of an elegant electro-pneumatic instrument. Organs built by Ernest Skinner have terrific keyboards. They have large, even gracious playing surfaces. Sharp keys are tapered front to back, allowing plenty of space for piston buttons without having the distance between the keyboards be too great. There is a carefully constructed and regulated “pluck” known affectionately as “tracker touch.” This is created by a spring that toggles as the key travels down and up, producing an accurate and subtle “click” in the motion of the key.
In the Skinner keyboard, the pluck is mechanically unrelated to the making of the contact—the function that actually makes the organ note play—but it’s essential that the keyboard be adjusted and regulated so that the relationship between the pluck and the action point is consistent from note to note. If it’s not, your carefully issued scale cannot possibly be even.
Keyboards can be decorated with lines scored in the surfaces or polished to smooth perfection. They can have light-colored naturals and dark-colored sharps, or the reverse. The playing surfaces are typically made of exotic materials—cow bone, ivory, ebony, boxwood, fruit wood (pear is especially nice)—because of the qualities of hardness and stability that is consistent with tight and close grain. It’s amazing to think that the amount of friction that can develop between human fingers and a hard surface like ivory or ebony can cause wear, but anyone who has played on an organ that’s been used frequently over 30 or 40 years is familiar with the “dips” worn in the keys. It’s especially common in the “hymnal” range of an organ keyboard, cº–c2. In my experience, organs in seminary chapels are the most heavily used—it would be usual for there to be two or three services each day—and there I’ve seen holes worn right through the ivory key covering. And once you’ve worn through the ivory, you tear through the wood very quickly and the edges of the ivory around the hole are as sharp as knives.
Keyboards are typically made of soft, straight-grained wood—spruce and basswood are favorites. Boards are glued together to make a “blank,” a solid panel the width of the keyboard. The boards should be chosen as “slab” grain—when you look at the ends of the boards, you see that the wood is cut so the lines of the growth rings are parallel with the tops of the keys, not the sides. As wood warps away from the center of the tree, keys made with slab grain wood can only warp up and down, not side to side. Such warping affects the regulation of keyboard springs and contacts, but makes it impossible for the keys to warp into one another and bind. This matters.
The keyboard frame comprises two “key cheeks” (the side rails of the frame that protrude to form the ends of the keyboards), and usually a front guide rail and a balance rail. The keyboard blank is fitted to the frame. The layout of the keys is drawn on the board, and the positions for guide and balance pins are marked. The holes for the pins are drilled through both blank and frame. Some craftsmen drill the balance pin holes through the top of the keyboard blank and into the frame, then drill the guide pin holes through the bottom of the frame into the bottom of the keyboard blank. This keeps the guide pin holes from going through the top of the key where you would most likely be able to see a hint of them through the keyboard covering. The surfaces of the naturals are glued on the blanks, sanded flat and given a round of polishing, the keys are cut apart, the sharps are glued on, and everything is polished. Sounds simple? Trying putting wet glue between an ebony sharp and a basswood key body and then tightening a clamp to help the glue set. The glue acts as a lubricant and the ebony sharp slides sideways. Many hours of filing, fitting, buffing, regulating, and adjusting complete the picture.
A well-made keyboard is a work of art, a vehicle for the relationship between the player and the instrument. It should feel familiar and welcoming under one’s hands, and should provide smooth, accurate, and flawless response whether the instrument has mechanical or electric keyboard action.
Take care of your keyboards. When I tune your organ I can tell how serious you are by how you keep the console. Is your console a combination between desk and boudoir, loaded with personal googahs and enough office supplies to run a university? Or is it the musician’s beloved seat where the intimacy of the relationship with your instrument is fostered and nurtured? Don’t bring food and drink to the organ console. Spills will seriously affect the responsiveness of your keyboards. Crumbs will attract critters—and critters will set up house in the console making their nests from felt stolen from keyboard bushings. It is absolutely common for the organ technician to find dirty little trails left by generations of mice running across the keyboards inside the console. One pictures Daddy Mouse saying to Mommy Mouse, “If he plays that Widor one more time . . . ”
Clean your keyboards—not just the top surfaces, but the sides of the keys as well. Use a paper towel or soft cloth rag, moisten it, put a tiny bit of mild soap on it, wring it out with all the force you can muster, and wipe the keys clean. Use a second rag, slightly moist, to remove any soap film, but remember that excessive moisture may spoil the glue that holds on the ivories. You’ll feel refreshed the next time you play.
Aeolus was a mythical Greek deity who was cited by Homer in The Odyssey for giving Odysseus a bag of captured wind to help him sail back across the Ionian Sea to Ithaca. The keyboard puts the captured wind at the player’s fingertips. We may not be placing our instrument between our brains and our beating hearts and lovingly stretching our arms around its neck (does Mr. Steinhardt ever feel like strangling his beloved?). Instead, we are doing nothing less than conjuring the very wind by wiggling our fingers. Nice work.

In the wind . . .

John Bishop
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They don’t make ’em like they used to.

We often come across consumer products that disappoint us. You buy it, get it home, and find that it’s not what you were expecting. Maybe it’s a pair of shoes whose soles come off too soon. Maybe it’s a toaster that won’t stay down. My parents lived in the house in which I grew up for more than 20 years, and the same two telephones were in the same two places with the same single phone number the whole time. I hate to admit how many phone numbers I’m paying for now (personal, business, and fax lines in two locations plus a mobile phone), but I seem to be buying new phones every few months. Those sturdy phones in my parents’ house had two functions—you could pick up the handset to make a call, or you pick up the handset to answer a call. And they had real analog bells in them that rang for incoming calls! The phones I buy now have speed-dial memories, hold buttons, caller ID, conferencing, multiple lines with distinguishable rings, volume controls, redial, busy redial, call forwarding, etc., etc. I appreciate and use all those features, but the phones don’t seem to last as long.

Is newer better?

Likewise, my car has hundreds of features that were unheard of twenty years ago. When I opened the hood of my first car, I could see an engine. My present car has a maze of sensors, hoses, filters, and electronic gadgets under the hood. All that technology means that the engine runs smoothly and reliably and requires very little maintenance. But a breakdown is likely to be caused by a seemingly mysterious failed sensor or a vacuum leak rather than a good old mechanical problem. And there must be hundreds of gadgets for comfort and convenience—electric this, heated that. I’ve had the car about eight months and I still find myself saying, “I didn’t know it did that.” I have to admit that I’d prefer not to give up all the snazzy features in favor of yesterday’s simplicity. I hope my next car will have a heater for the washer fluid!
A modern organbuilder faces this issue daily. We hope and intend that our work will last for generations, but we have to rely on materials that can be substandard. Look at the biggest pipes of the 16' Open Wood Diapason in an organ built by Ernest Skinner, each made of four knot-free boards 18" wide. The trees that yielded that lumber have all been turned into organ pipes. I maintain a Skinner organ in Reading, Massachusetts that was built in 1915 and still has its original reservoir and pouch leather. Ninety-one years! We have to work within a modern economic system that sometimes seems not to value quality. And we have to develop and create a specialized workforce. America’s educational system has no provision for training organbuilders. Each new worker has to be recruited, educated, trained, and sustained in a craft that typically builds very expensive products from rare and expensive materials using donated money.
But all that effort is worth it—pipe organ building is one facet of modern life where they do make ’em like they used to. It’s a privilege to be involved in a field in which excellence is the norm, in which personal craftsmanship is truly valued, in which the client or patron expects excellence. I especially value those conversations with my organbuilding colleagues in which we reflect on the high standards of our predecessors and how to emulate them in today’s world. That’s not an easy thing to achieve, and it does not happen without continual concentrated effort. A good organ is not an accident.
My work with the Organ Clearing House keeps me in regular contact with the best of older pipe organs, and I always marvel at the signs of yesterday’s craftsmanship. For example, there was something special about the way workers in E. & G. G. Hook’s factory sharpened their pencils. You can see this throughout their organs wherever a mortise was marked—those pencils were really sharp, and you know there were no fool-proof electric pencil sharpeners in sight, and you also know there were no plastic pencils with the lead out-of-center. Focusing on pencils may seem obsessive, but in order for a 19th-century pencil to be sharp, someone had to sharpen a knife by hand. Many modern craftspeople rely on factory-produced, laser-sharpened disposable blades for manual tasks such as cutting and skiving leather. And for less than ten dollars you can buy a pair of scissors that will cut just about anything. Achieving the “old days” levels of accuracy with hand-made, hand-sharpened tools is a reflection of a true craftsman.

They pretend to make them like they used to.

We rely on high-tech power equipment for processes that were once done by hand. With my family I once visited one of those reconstructed, restored historical villages that had been transformed into a modern museum. Staff people were walking about in historic dress demonstrating traditional crafts such as spinning, weaving, and candle-making. There was a reproduction of an old woodworking shop, and the docent proudly told us how the shop was producing the millwork being used for the restoration of buildings throughout the village. Next to a treadle-powered lathe there was an impressive pile of precisely turned poplar balustrades intended for a large curving staircase and balcony. I was suspicious. I stood up on a bench and peered over a low wall to see a state-of-the-art modern workshop with all the best power equipment. I imagined that the fellow in the leather apron at the foot-powered lathe had been spinning the same piece of wood for weeks.
When I was first working in organ shops we turned a lot of screws by hand (Popeye arms!), and we had Yankee® Screwdrivers—long-handled tools with a built in ratchet that you pumped up and down to drive a screw. Boy, did it make a mess of your wood when the bit jumped out of the slot in the screw-head! Then we cut off the end of a screwdriver and put it in the chuck of an electric drill. Then we had factory-made screwdriver bits that came in big sets. Then we had electric screwdrivers—a rig that looked like a drill but included an adjustable clutch to prevent you from stripping the thread in the wood. Now we have powerful rechargeable batteries that allow a wide variety of cordless power hand tools. (See Photo 1.) I’ve joked many times to younger workers that “when I was a kid we had wires hanging out of our screwdrivers.” When rechargeable batteries were first introduced the technology was inadequate. There was hardly enough power to turn a tough screw, and the charge didn’t last long enough to be practical. But now, with a quick-charger and a couple spare batteries you can work all day without interruption. I recently added to my bag of tricks a battery charger that plugs into my car’s twelve-volt outlets. (And by the way, this car has outlets all over the place.) When I leave a service call with a dead battery, it’s recharged before I get to the next stop.

You think that’s old?

My wife and I just got home from a vacation in Greece. We were fascinated by the culture, awed by the landscape, and charmed by the sunny atmosphere of the islands. But visiting the historic archeological sites was simply humbling. I routinely work with organs that are 150 years old. I live in New England where we are surrounded by buildings and artifacts from the establishment of the original colonies and the Revolutionary War. There are a few buildings around that are close to 400 years old. The history of the ancient city of Delphi is traced to the beginning of the 12th century B.C. when the Dorians arrived in Greece, and the surviving buildings date from around 500 B.C. There is a 5,000-seat theater built in the fourth century B.C.—simply stunning. (See Photo 2.) As a tourist, one can stand on the “stage” at the focus of that vast amphitheater and imagine an enthusiastic crowd cheering you as a favorite actor or musician. Or walk on the field enclosed by the 7,000-seat stadium and imagine an ancient athletic contest. (Several fellow tourists ran a high-energy race.) But what the guide books cannot prepare you for is the topography. These massive buildings are made of stone—huge pieces of stone—and the sites are almost all dramatic, steep, even scary mountainsides. The floor of one building is above the roof of the one next door. One walks from place to place exhausted by the combination of the brilliant Mediterranean sun and the weight of the camera bag, water bottles, and the wildly steep uneven steps. Add to that exertion the thought of carrying the rocks to build the buildings. No payloaders, no Bobcats®, no conveyor belts, no dynamite—just wheels, levers, and muscle.1
The ancient town at Mycenae was first settled around 1950 B.C., with major development or organization in about 1200 B.C. It includes Agamemnon’s citadel and royal palace, and features a sophisticated system of cisterns and aqueducts to supply drinking water through the site. The skill of the stone masons who built the many structures is especially notable. How they were able to achieve perfect joints between stones the size of small automobiles and then hoist them into place is hard to imagine. I couldn’t help thinking of the Organ Clearing House crew with towers of rented scaffolding and electric hoists to lower windchests out of an organ chamber. The adjoining museum displays a collection of bronze tools—hammers, adzes, drills, chisels—that the craftsmen made and used in their work. To use a hand-held adze to create a perfectly flat surface on a ten-ton stone—they certainly don’t make them like they used to! (See Photo 3.)
I was particularly interested in the methods and philosophies regarding preservation and restoration. Two years ago I attended an excellent symposium in Winston-Salem, North Carolina on the occasion of the completion of the restoration by Taylor & Boody of an organ built in 1799–1800 by David Tannenberg. The instrument had been rediscovered in storage in a building that is part of Old Salem (another wonderful museum-village, not the site of the earlier mentioned balustrade caper!) and was returned to spectacular playing condition. The restoration was impeccably documented by Taylor & Boody, and they made fascinating presentations of the various tasks and challenges they faced. Some new parts had to be fabricated, but they went to extraordinary lengths to “re-round” literally flattened tin façade pipes, to reconstruct the geometry of the keyboards, and to establish the pitch of the organ. Moravian archives at Old Salem even contain a handwritten letter from Tannenberg to the church describing how to set the temperament and tune the organ.
But a side debate (exercised at length between friends and colleagues over dinner) included the suggestion that true preservation would not undertake to reconstruct the organ but to catalogue, measure, and display the array of parts. To presume to make new parts and to make assumptions about details like key travel would be to intrude on history.
In our work with historic organs we continually face similar questions. When we relocate an historic organ the intention is typically that the instrument should retain its historicity as much as possible, but also should be useful and reliable as a musical instrument, available for regular use by any organist. So can we justify adapting an instrument for modern use? Many modern organists are devoted to the use of combination actions—are we preserving an antique instrument if we adapt it to include an electric stop-action, or are we desecrating it?
Many of the monuments we visited in Greece are simply ruins today—mazes of stone foundations that allow us to surmise what life might have been like in an ancient village. Houses are supposed to have been occupied by merchants or by royalty. Local hierarchies are assumed based on the relative altitude of residences—the royalty lived at the top of the hill, laborers and merchants at the bottom—literally upper and lower classes.
But other sites are in the process of reconstruction. Perhaps the most dramatic of these is the Parthenon, situated on the Acropolis high above Athens. (See Photo 4.) Originally settled around 5000 B.C., the Acropolis is one of Greece’s earliest settlements. Throughout the ensuing centuries the site was fought over, developed and re-developed. Geologically it’s a large flat area, very high up, with very steep walls—a comfortable area to settle that’s difficult to reach and easy to defend. And the best part is there’s plenty of water—a feature common to all those barricaded hilltop cities. The Parthenon was built by Pericles around 450 B.C., made possible by the economic strength of the Delian Treasury that resulted from the formation of the Delian League of city-states. A thousand years later it was converted for Christian worship by the Emperor Justinian, and in the 17th century the Venetian army laid siege to the occupying Turks. In 1684, the Turks destroyed the Temple of Athena Nike (another of the grand structures on the Acropolis) to aid their defensive tactics, and in 1687 a Venetian bombardment exploded a Turkish magazine located within the Parthenon, blowing off its roof and reducing to rubble a 2,000-year-old monument. Today a massive restoration effort is underway, funded by the Greek government, the European Union, and “other contributions.”2
I was fascinated by the restoration site. (See Photo 5.) A huge construction crane is painted the same color as the Parthenon’s marble and housed at night crouching against the side of the building so as not to interfere with the skyline. The stone-workers’ workshops are housed in several low buildings, again designed with discreet profiles. Railroad tracks crisscross the site providing sturdy platforms for material handling. It’s a big effort when each piece of your project is weighed in tons rather than pounds. The rubble has been sorted into piles, individual pieces numbered and catalogued as to where in the building they originated. And fragments of stones have been returned to their original dimensions with new material (both marble and composite material) added. I was especially interested in the restoration with regard to what we learned about the Tannenberg organ in Winston-Salem. New material was added when necessary so the restoration would allow us to appreciate the monument in its original form. (See Photo 6.)
We visited the medieval Byzantine city of Mystra situated on another steep hill, this time on the outskirts of Sparta. There’s a castle at the very top (another steamer of a climb), several stunning churches and monasteries with breathtaking frescos, a royal palace, and the foundations of the houses and businesses that sheltered and supported a community of more than 20,000 inhabitants. The church of Ayia Sofia, built in 1350, features an elaborate floor made of polychrome marble. We were astonished that the public is allowed to walk on it! Like the Acropolis, this ancient city is illuminated at night, visible for many miles in every direction. There are halogen light fixtures mounted all around the hillside with conduit and wiring snaking through the ancient buildings. Nestled in a little neighborhood of the ruins of a dozen or so ancient houses I saw a large transformer shed, humming quietly in the wind.
How do we decide what modern concessions will enhance our ancient monuments?

There must be a better way.

Reflect on all the fancy sophisticated tools used by modern organbuilders. Power everything, laser levels, sophisticated hydraulics, digital measuring. There are no cars allowed on the Greek island of Idra in the Aegean Sea. On a Monday morning we sat at a waterfront café waiting for the ferry that would take us back to the mainland watching a construction crew loading bricks and bags of sand and cement onto donkeys. (See Photo 7.) How do you like this guy leading his brick-laden donkeys while making a call on his cell phone!

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