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Although the organ has been making a lot of music since first coming alive last July, it was clear that the two blowers that were powering the organ did not output enough wind. As a general rule of thumb, you want to design your static pressure with at least two inches of water column higher than your highest regulated pressure. In this instrument's case, the Tuba is on 15". The two original blowers output 12" and 16" of water column. Though Mark Herman, a new 10 h.p. blower was acquired for the instrument. We just had to drive an hour south of Minneapolis, in the middle of corn fields to get it! The fans were in rusty shape but cleaned up well with a chemical treatment and a lot of scrubbing. There are two 10" wind lines that come out of the blower room and go to the chamber. The previous two blowers each output into their own baffle box and then out to one of the feed pipes. A new baffle box (to quiet the wind noise down) was constructed and installed, connecting both lines together. The last challenge was on the power side of things... the existing VFDs were not rated for a 10 horse motor, so a new ABB drive was acquired and installed to control the much larger motor. Now that the new blower is in place and outputting 19.5" of water column, I realized how under-winded the organ was! It seems like a new instrument to me and I look forward to sharing it during the ATOS convention next month!
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On September 21st and 22nd, we welcomed over 100 people into our home for two dedication concerts played by Zach Frame. It was quite fitting for Zach to play these having been involved with this project from the start. Saturday evening focused on those who helped out with the project (the list totaled 33) and their guests. As a thank you, we catered in a dinner with concert to follow. Sunday was open for everyone else interested in experiencing the instrument. These concerts also served as a kick off for raising funds for our newly formed foundation. Board members were on hand to answer questions and enough was raised to fulfill a scholarship. We look forward to seeing how this instrument can be used for good in the future. This past month, a short list was generated (which is getting shorter!). The organ has been getting played nearly daily and things are starting to settle in. Reeds have been tuned multiple times as they play in. The most notable accomplishment was to receive the bottom six pipes of the VDO, VDO Celeste and Salicional from Andy Meyer. Without surprise, his work turned out to be amazing. Truly a work of art. When I picked them up, he mentioned that he didn’t have time to clean the pipes and suggested (in a not so suggesting way) that I WILL be cleaning these pipes up, right? Of course. They were wiped down with Simple Green, then CLR and steel wool to get rid of the zinc oxide and finally some car wax (Andy’s recommendation). Safer and less toxic than the original lacquer finish. At the same time that I was working on those, Zach Frame soldered many pipes, repairing various issues with his new pipe soldering setup. This included a diaphone that until this point, was not installed in the organ due to its support structure being cracked. With those pipes installed, I needed to get an updated chamber photo! It’s Alive!!! After the better part of 14 years, this hobby project has finally taken life. In many ways it is comparable to the birth of a child, although we only had to wait nine months for those to arrive! On July 4th, 2024, the organ came to life and shook the entire house for the first time. Quite literally, the immense power from the pipes and tremulants below shake the floor, windows, mounted tvs and closed doors. I will need to apply felt to the door frames to prevent rattling. July 4th seems to be fitting too as this was my American dream. Really, I consider this instrument a gift and one that is intended to be shared. Not much about how we obtained it or how our house was constructed around it makes much logical sense, so we took that to be a sign from above and together, along with some friends, founded the Preserve Music Foundation, a 501(c)(3) non-profit organization dedicated to enriching lives through the assistance, support, and encouragement of music educators, performers, and students in Wisconsin. We specifically want to focus on two things to start: (1) a scholarship program for graduating high school students interested in pursuing music performance or education, and (2) an instrument program that grants instruments to those individuals or schools that cannot afford them. Among other fundraising activities, we intend to use the organ for concerts and have a free will offering to support the foundation (no pressure!). More about the foundation can be found here: https://www.preserve-music.org/ Back to the details. The post horn trem was installed and wired into the organ. Next, the remaining offsets were winded. Oh yea, and the bottles too. Once everything was on wind, it was time to prep the manual chests for pipes! This meant installing “top hats”, pins, rack boards and pipe racking. Once that was complete, it was time for the pipes! By the end of the day on July 3rd, the back (solo) chest had pipes. On July 4th, the remaining pipes were placed on the main chest. A four hour tuning session followed the pipe planting activities and it was time to make some sound! Zach Frame started playing something quiet and immediately it was noted how well the swell shutters controlled volume. Just to check volume levels (four kids and Lindsay were sleeping at the time…), I walked over to the kids rooms and quickly noticed that the varying pressure caused by the tremulants were causing the bedroom doors to rattle quite loudly. Needless to say, the organ wasn’t really opened up until the next morning. The bottles were the last thing to get tweaked. Some needed to be shimmed to speak; some needed to be tuned (add or remove mineral oil), and overall, the pressure needed to be increased. I was able to get them up to 9 inches of water column until the direct electric magnets no longer pulled in. Needless to say, the little beer bottles are quite audible now. Of course, there is a punch list of things to resolve / issues to fix, but the organ plays. We have scheduled a dedication concert in September for all those who helped with the project (a running list is now at 33 people). On September 22nd at 2pm, we will open our doors to whomever else would like to experience the instrument. None other than Zach Frame, the one who has helped with this journey for all of these years will play the concert. Mark your calendars! This month a shelf was made for the new curtain valve reservoir in the closet to feed the bottles and future tone chute bourdon, which will be used for a resultant effect (very low notes that simulate a 32’ stop). All trems were placed in the organ minus the post horn trem that needed to be rebuilt. An 18/2 cable was run from the spreader board between the two shade frames and each trem. The Clarinet/Diapason, Strings & Flute, Vox and Tuba trems were all winded. Pin addresses for the trems were programmed into Uniflex so now the organ is starting to come to life when a piston is pushed! After laying out some pipes, it was determined that I was missing a G# in the Tuba Horn. I was also missing some sleigh bells that had been cracked, missing or really out of tune. At the same time, Terry Kleven and Bob Swaney of Century Pipe Organ in Minneapolis had a Uniflex issue in the Heights Theatre up by them. A deal was made for me to fix the Uniflex issue in Minneapolis in exchange for the bells and Tuba pipe I was missing. Word of this got out and add to the mix two chests that needed to come down to the Organ Piper and a bunch of diaphone pipes for John Cornue… now the trip included a 16’ Penske truck that was split three ways! Zach Frame and I hit the road and spent two days moving organ parts and making the Heights organ happy again. Upon unloading at the organ piper, we happened to spot a dirty looking pipe in the corner of the garage. Upon further inspection, it turned out to be… a Wurtlizer Tuba pipe… you guessed it… G#. God has a sense of humor. Another day this month was spent at the organ piper for some pipe swapping. First the post horn. My post horn was not original to the El Capitan organ, but was a newer moeller post horn voiced on 10”. The restaurant post horn was the same thing… except it was mitered to fit under a small ceiling and mine wasn’t mitered at all. Since the restaurant has ceiling height and my basement does not, it was a like for like trade to avoid cutting up a set of pipes to make them fit. Once they were racked and tuned, it was determined that the pipes actually sounded better in the restaurant as the bottom notes actually were able to get out over the rest of the pipes in front of the post horn. Next time you are eating pizza and listening… see if you can tell! The second swap was a few notes of the tuba. Not the reeds/boots, just the resonators, which again, were mitered on the restaurant’s organ whereas mine were not. While the pipes were removed, proper racking for a tuba was installed, whereas the restaurant previously had Style D Trumpet racking holding up the Tuba, which kind of worked, but wasn’t the proper racking for the application. The proper racking fits the tuba much better and looks correct. Finally, with Derek at Organ Piper doing some spring cleaning ahead of a garage remodeling project, spare parts were reviewed. At the end of the day, I was able to get a spare organ ladder, which will be used in the back corner of the chamber to get up onto the percussion shelf/platform. Finally, the organ now has a video system installed so that an image of what is going on in the music room can be displayed on the TV in the living room and basement for overflow seating and so that everyone can see things moving in the chamber. Right now the system only has two cameras, but more will be added later. This month, wiring on the rear toy counter was completed. We can now make the organ sound like a marching band drum section! The Diaphone racking was assembled, which was made from scratch based on engineering diagrams in the Wurlitzer book and measurements taken / verified from other organs. This included the quarter inch steel rods that the pipes hook onto. With that done, the diaphone chest was screwed down, racking installed and pipes planted! The last Bourdon (bottom of the flute) chest went in, along with the flute, diaphone, salicional and VDO/Celeste offset chests. All were wired and a final cable was run for the two treble offsets. With that, the relay wiring is completed! All documentation has been updated, printed out and placed in a binder for reference. The Uniflex relay got a new “Pipes” user added with all pin addresses programmed in, versus calling for Hauptwerk digital ranks. As soon as pipes are planted on chests, this user can be loaded to actually play them. The bottom six notes of the VDO / Celeste and Salicional ranks have been packed in a crate for Andy Meyer to miter them to fit. As you can see by the picture of the strings, we simply ran out of ceiling height. Before the string chests went in, two reservoirs were removed from their trunks so that the proper holes could be made. This proved to be most difficult as the lids were fastened down with cleats, rather than screwed down from above. A couple of hours elapsed on the floor dealing with that challenge. Once removed, flanges and stub pipes were installed so that future connections to chests would be easier given that the VDO offset is conveniently located in front of the reservoir like a wall! While putting PVC pipe together, the Post Horn chest was winded. Finally, the walk board framing between manual chests was installed. A dowel jig was used, along with my newly acquired reproduction fish plates to strengthen the supports. With all of that done, a hopefully “final” order of pvc flanges were ordered to make the rest of the connections. A curtain reservoir was also ordered to run the bottles at 4” of wind pressure. This month, work started on rebuilding the two tremulants that are in bad shape. All of the remaining pieces that needed to be sprayed in the temporary spray booth were completed, including the decking. As soon as the finish dried, all of the puzzle pieces that make up the platform were assembled in place. Aside from two pieces that are screwed down, all other panels are removable for servicing the reservoirs underneath. It is really nice to be able to walk around on top now! Taking advantage of that decking, the 8’ Tibia offset was wired. Moving to the back of the chamber, the Ophicleide chests, racking and pipes were installed. Temporary winding was removed from the glockenspiel (used for the Christmas program). With some newly located fishplates, the glockenspiel was moved forward and secured. Rubber cloth was purchased and with that, the back trap trunk was completed! While it was out, the front trunk also received new rubber cloth as the old material was wearing out and had several leaks. With the back trap trunk secured, a few holes were drilled for wind lines. This trunk is now getting wind fed from the front trunk and feeds the glockenspiel, base/kettle and snare drums. Towards the end of a very productive day, the diapason offset was put in place along with the associated racking and pipes. Finally, track lighting was extended to the back of the platform and along the back of the chamber so that the walkway behind the marimba could be properly lit. This month started out with repairing some Ophicleide pipes (bottom end of the Tuba) that had collapsed under their own weight (high lead content in the resonators). Instead of looking circular at the top, they looked like squished eggs. Thanks to my friend John Cornue, he was able to persuade them to retake their original form. This was a very interesting process to watch and certainly yet another artform. Thanks John! With the rest of the lumber on hand, a temporary spray booth was constructed in the basement out of plastic sheeting and some fans out our future bedroom egress window. With those supplies, some staples and tape, we were able to create a negative pressure enclosure to spray in. The two large pieces of the platform that stay stationary were completed so the 8’ Tibia offset could be installed. Finally some more pipes! The second trap trunk was also constructed, along with racking for the Diaphone and Ophicleide as the originals did not come with the organ. Thanks to Zach for all of the help with these things! His table saw certainly isn’t a stranger to this project… Another few pieces missing were some metal fishplates. Fortunately, there is a metal fabrication shop near us that was able to make copies of an original. Finally, the three remaining buttons that took two months to get and another month to have engraved were delivered and installed in the console drawer. This month’s progress can be summarized by lumber, platform and marimba. During our last large work day in December, we came up with a shopping list for the remaining poplar boards to have milled and plywood needed for the platform. Badger Hardwoods of Walworth came to the rescue again for the milled poplar boards (to match Wurlitzer’s spec) and Alpine Plywood of Milwaukee supplied the one inch-thick aspen sheets. As you may expect, these were heavy, as is everything pipe organ! A full day was spent cutting up the plywood into jigsaw puzzle pieces to cover the platform up. Each panel was made to fit tightly so as to not allow any sound out. With the exception of two panels, all are removable to service the reservoirs underneath. An additional sheet of plywood was cut up for the second trap trunk and another sheet was used for two walkboards. These will now need to be sanded and spray shellacked. Finally, it was decided that the marimba needed to be rebuilt the rest of the way, due to excessive wind leaks. Although some of the marimba was rebuilt before we got the organ, there were many pieces that remained on original leather, surrounded by an abundance of coal dust. The amount of pieces required to strike each marimba bar is simply amazing to me. Since the last update, a full day (until midnight if I recall correctly) was spent winding the remaining percussions and traps. Some additional wiring was needed for the crash cymbal, tap/roll cymbal and tambourine. A last minute “we should do this too” connection was the hi-hat. It was a long day but much was accomplished! After things were alive, a “short list” of things to fix was made with t-minus four days to go before our concert. When the fire gong and wood block pneumatics were re-leathered previously, there wasn’t enough leather put onto the secondaries, so they inflated but didn’t travel far enough to strike either the sheet of brass for the fire gong or the wood block. Releathering those proved very difficult as the wrong type of glue was used. One pneumatic took me over an hour to get the old stuff off and wood prepared for the new leather. With those things working, the next thing I focused on was to make the sleigh bells work better (this is the season for those afterall!). Many needed valve adjustments and just about all needed new armatures (the old ones were very dirty). While I was this far in, all magnet caps were removed, port holes milled (to make them smooth) and all new armatures installed. Finally, reiteration contacts were wired in for the fire gong, castanets and tambourine. Although the sleigh bells have reiteration contacts on the action, I chose to use Uniflex to make these notes reiterate. Through the software, custom reiteration pulse timing can be set per note. Lower notes are pulsed longer, whereas higher notes are pulsed faster. Another plug for Uniflex! On December 9th, we welcomed 67 people for our second annual Christmas concert featuring Zach Frame at the console. Special thanks to Mike Jacklin and our neighbors, the Leep’s, for borrowing us padded folding chairs. To fit that many chairs in, we removed all the furniture in the music room, dining room table and pushed our large couch across the room. We were overwhelmed with the amount of food that was brought. At the end of the night, we were left with an entire island filled with various dishes. Thanks to everyone who brought something! What has become a tradition is the creation of an eCard consisting of a video recording of one of the songs played. Here is a link to this year’s video: https://www.youtube.com/watch?v=wRtnFy4mNck |
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