Complete rebuild was needed for this piece. Chime tubes will be fitted once the action is mounted in the tone chute.
Much work has been completed since the last update. For starters, the chamber now has a wall on the front of it! Given the large opening for the swell shades that is about bar height… my wife asked when the drinks were going to be served. After putting that wall up, the idea didn’t seem too bad! As always, my assistant, Ella was there to help in any way possible.
Work has also progressed with the winding system with the remainder of the 10” schedule 40 PVC arriving. Finally, the chime action has been completely disassembled and is in the process of being rebuilt. A recommendation from Jeff Weiler’s shop was to get a spool of 1/16” aircraft cable and ferrules / crimp tool. These would be used in place of string to tie the chime tubes. The size of the 1/16” ferrules just fit inside of the tube so they are not visible from looking at it. The advantage here is that you don’t have to worry about tubes falling down when the string fails.
Thanks to EMS Industrial for constructing the control panel for the organ. Although quite unnecessary, it will sure be neat to watch the meters dance around when the organ fires up and plays! The panel offers readings on logic rectifier voltage, magnet rectifier volts and amps, blower 1, 2 and vacuum pump wind and controls for the frequency drives that power the blowers. In addition to those functions, you can manually start the blowers individually as well as the rectifiers and vacuum pump. The instrument will normally be controlled by a single switch next to the relay counter upstairs.... but that is boring in nature so thus this panel!
After starting this project several months ago, it is finally finished thanks to the new primary box gaskets that were punched at Jeff Weiler's shop.
First off, thanks to my friend Gary Bieck for giving me this Wurlitzer Shuffle. Second, to answer the question of what is a Wurlitzer Shuffle. To explain, I'll describe what a Wurlitzer Surf is first. A surf is a box that is typically attached to a wind trunk, operating on static pressure. This box has a pneumatic inside that slides a piece of wood back and forth, allowing wind to escape from the box through a slit in the top. In-line with the slit is a piece of sheet metal that the wind passes over as it rushes out. The large pneumatic inside has a "bleed" screw that controls the rate it moves. The end effect sounds similar to the surf rolling in and out. Now that you understand a surf, apply the exact same concept (and design) to the shuffle, with the addition of a primary box that allows the large pneumatic inside to move quickly. This makes it possible to play the shuffle rhythmically. This particular shuffle got hit with water at some point during its life. Therefore, wood glue and lots of clamps were deployed during the restoration of this unit.
Finished up the crash cymbal action. This one was an interesting design that I haven't seen up until this point. A double primary valve exists to fire the secondary. This is also the first time I experienced the self-tapping valves that Wurlitzer used in certain applications.
I had the opportunity to tour the shops of JL Weiler in Chicago. While there, I was introduced to the punch press, a machine that is used to punch holes in leather. In the case of an organ, there are many gaskets that need holes punched in certain places for screws to pass and wind channeling to function. Primary boxes contain three specialized gaskets with many varying sized holes in each. Although it is possible to punch these out by hand, a punch press greatly speeds things up. Arrangements were made to return with enough leather to punch 66 sets of primary box gaskets (198 total). Thank you Jeff Weiler and Mike Jacklin for making the photo below possible...!
For historical reference, the wood pictured below was had for a low price of only $778.93. About four times the cost as it was a year prior.
Due to COVID pandemic delays, the 10 replacement SAMs that were ordered back in November of 2020 finally arrived! They have been installed in the console to replace ones with burnt out coils. These are what the multi-colored stop tabs get mounted to. The coils with black foil around them are the magnets that move the switches up and down (on and off). The actual switch that tells the Uniflex relay that the stop is on or off is located towards the bottom of the board as the below image is oriented. It is called a reed switch and consists of two tiny pieces of metal that are moved together or apart based on magnetic fields produced by the magnets that are just above the switch.