ORGAN BUILDING

IOR
AMATEURS
ORGAN BUILDING
IOR
AMATEURS
A
!"#$%&$#' )*&+, -." /.0,12."3,"4
CONTAINING SPECIIICATIONS, DESIGNS, AND IULL
INSTRUCTIONS IOR MAKING EVERY PORTION
OI THE INSTRUMENT.
BY
MARK WICKS
!"#$ &'() #!& $*+,)(, "--*.#)/#"&+. /+,
(01-/+/#&)2 ,"/3)/4.5
+
Bardon Enterprises
Portsmouth
Iirst puhlished hy Ward, Lock 8 Co., London.
Copyriht this edition acc hy Bardon Enterprises.
This edition puhlished in acc hy Bardon Enterprises.
All rihts reserved. No part ol this puhlica-
tion may he reproduced, stored in a retrieval
system, or transmitted, in any lorm or hy any
means, electronic, mechanical, photocopyin,
recordin or otherwise, without the prior
permission ol the puhlishers.
ISBN . -qcaaaa-a-c
Typeset and printed in Enland
hy Bardon Enterprises.
Bound in Enland hy Ronarteuro.
16789:6;8<= $>:?9<@7A= (BCD>BE5
!""#$%%&&&'()*+,-./-"/*#*01/1'2,'34
v
PREIACE.
+
N suhmittin this little work to the puhlic I must, in the nrst
instance, warn the reader that it is not written with the inten-
tion ol dealin exhaustively with oran huildin enerally, hut,
as its title implies, only with that particular phase which comes
within the means and scope ol an intellient amateur workman.
Therelore, such rennements as electric and pneumatic actions, not
hein required in small instruments, nnd no place in this work, hut
everythin ol interest to a home-worker is touched upon in a thor-
ouhly practical manner.
There are many works on the suhject to which huilders, purchas-
ers, or eneral readers may resort lor inlormation respectin orans,
hut the instructions contained in most ol these works hein limited
to eneral, and olten vaue, description, are ol little service to an
ordinary amateur desirous ol huildin the instrument himsell , as in
most cases the idea ol huildin an oran at home is taken up hy
persons havin little knowlede ol the construction ol the instrument
which they so ardently desire to possess. It is indeed rather surpris-
in that there is not a larer supply ol literature dealin with this
suhject lrom an amateur's point ol view, lor it is a matter which is
constantly claimin the attention ol youn men ol mechanical pro-
clivities, and also one which exercises an astonishin and peculiar
lascination over them. But heyond isolated papers in maazines and
the little manual ol the Rev. W. E. Dickson, there does not appear to
he anythin which can rihtly he considered as meetin the require-
ments ol persons ol the class relerred to. It is with the ohject ol
supplyin this want that I have heen induced to compile the little
manual which now seeks the sullraes ol home-workers. As an
amateur oran-huilder I may lairly claim to have some knowlede ol
the necessities ol that class, and ol the dilnculties which heset them
!
ORGAN BUILDING IOR AMATEURS. vi
at every turn. It has heen my endeavour to smooth away those
dilnculties hy descrihin every part ol the instrument in the lullest
detail, and hy supplementin the instructions, wherever practicahle,
with carelully drawn illustrations.
The method ol makin pipes ol paper, which is an invention ol
my own, will, I trust, prove a hoon to amateurs, especially those ol
limited means, as hy makin pipes ol this material the most expen-
sive item in the cost ol the instrument is reduced to a comparatively
nominal sum. I do not think I could adduce hetter testimony ol their
elnciency than the lact that a practical oran-huilder, who is quite
unknown to me, has thouht it worth his while to take up the
manulacture ol these pipes, and to enlare his workshops lor the
purpose.
I would add that the care, patience, and perseverance devoted to
huildin even a small oran at home necessarily allord most valuahle
trainin to youn men, and the moral value ol the instrument itsell in
a home where children are rowin up cannot, I think, he over-
estimated.
uly, 88y.
vii
CONTENTS.
+
CHAP. PAGE
I. TOOLS AND APPLIANCESSPECIIICATIONS NEW METHOD OI
MAKING PIPES ......................................................................................................................
II. WOOD PIPES................................................................................................................................. a
III. PIPES OI METALCASTING BENCH AND CASTING BOX METAL
IOR PIPES MELTING METAL NECESSARY TOOLS SCALE
IOR CUTTING METAL IOR PIPESIORMATION OI SHEET
METAL INTO PIPES ........................................................................................................
IV. REED PIPES ....................................................................................................................................
V. SOUND-BOARD, WIND-CHEST, PALLETS, ETC. ................................................y
VI. THE BELLOWS.............................................................................................................................y
VII. THE BUILDING IRAME AND MANUAL ACTION.......................................... 8y
VIII. THE KEY-BOARD .................................................................................................................. c
IX. THE STOP ACTION AND COUPLERS ...................................................................... a
X. THE PEDAL ORGAN . SOUND-BOARD, AND PEDAL KEY-BOARD. a8
XI. PEDAL ACTION . COUPLER GREAT TO PEDALS ..........................................y
XII. THE SWELL, ETC.VENETIAN SWELLGRIDIRON SWELLBOX
SWELLTREMLANT.................................................................................................. 8
XIII. VOICING AND TONING DEIECTS AND THEIR REMEDIES...........y
XIV. TUNING........................................................................................................................................ y8
XV. THE CASEPIPE DECORATIONS.............................................................................. 8
XVI. DEIECTS GENERALLYLIST OI STOPS AND THEIR
COMBINATIONSADDITIONAL SPECIIICATIONS ..........................qq
viii
LIST OI SEPARATE IOLDING PLATES.
+
PAGE
Containin six desins IOR PIPE DECORATIONS, ..................................... F76B8@9?@AGA.
a. Containin nures -. DETAILS OI PAPER PIPES.................................... #6 H>GA ?>CA q
. Containin nures q-a8. DETAILS OI WOOD PIPES .............................. #6 H>GA ?>CA a
. Containin nures 6-y. DETAILS OI METAL PIPES .............................. #6 H>GA ?>CA y
. Containin nures q-y. COMPARATIVE SIZES OI PIPES, ETC. .......... #6 H>GA ?>CA
6. Containin nures y-8. DETAILS OI SOUND-BOARDS, ETC. ............ #6 H>GA ?>CA q
y. Containin nures 8a-8. DETAILS OI SOUND-BOARD, ETC. .............. #6 H>GA ?>CA 6q
8. Containin nures c-c. DETAILS OI BELLOWS................................. #6 H>GA ?>CA 8
q. Containin nures q-. DETAILS OI PEDAL ACTION..................... #6 H>GA ?>CA
c. Containin nure yc. LONGITUDINAL SECTION OI ORGAN........... #6 H>GA ?>CA q
Containin nures y-y. TRANSVERSE SECTION OI ORGAN, AND DETAILS OI
GRIDIRON SWELL ........................................................................................... #6 H>GA ?>CA
a. Containin nures y-8o. DETAILS OI VENETIAN AND BOX SWELLS AND
TREMULANT..................................................................................................... #6 H>GA ?>CA
. Containin nures q8, qq. DESIGN IOR ORGAN (No. ) ................ #6 H>GA ?>CA 8
. Containin nures ac, ac6. DESIGN IOR ORGAN (No. )................. #6 H>GA ?>CA qa
. Containin nure ac8, DESIGN IOR SMALL ORGAN WITH WOOD PIPES
................................................................................................................................ #6 H>GA ?>CA q

!"#$% '()*+)%# ,!" $-$./("0

+
CHAPTER I.
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4(#$&, &F 4/K"+3 1"1(.5
HERE are lew thins that possess more lascination lor the
amateur mechanic than a musical instrument, and lew, indeed,
that, il the work he well carried out, will so lully reward him
lor his patience and lahour. The oran, that acknowleded
kin amon keyed instruments, is ol such construction that every
portion ol it may he made hy a person possessin a little skill and a
lair amount ol patience and inenuity. In this respect it dillers lrom
the piano or harmonium, as in those instruments the really music
producin portions would not he placed to the credit ol the amateur,
hut would necessarily he purchased, whereas every pipe in the oran
could he made hy the amateur himsell.
Belore proceedin with the instructions lor the huildin ol the
instrument it will douhtless he well that I should indicate the princi-
pal appliances and tools required lor the work.
Iirst and loremost, a ood, nrm, and level hench is ahsolutely
necessary, and this should he at least 6 leet lon, or capahle ol hein
extended to that lenth hy means ol an end nap with nrm supports.
It must also he provided with the usual appliances lor holdin the
wood nrmly whilst it is hein planed, etc.
T
"
TOOLS AND APPLIANCES. a
We shall require one or two hand-saws lor rippin planks and lor
eneral sawin work, and also one lare and one small tenon saw.
Ol planes we must have at least three, viz. a jack-plane lor
rouh work, a tryin-plane lor planks and lor shootin joints, and a
smoothin-plane lor nnishin oll. In addition to these one or two
small American iron planes would he lound very uselul.
A tool commonly known as an old woman's tooth, or router,
will also he necessary lor clearin out and levellin roovins.
At least lour chisels, viz. . ! inch, " inch, # inch, and ! inch. One
or two ol the intermediate sizes and a " inch mortise chisel would he
very handy, hut are not ahsolutely necessary.
A oue or two, say $ inch and % inch, lor makin conductin
rooves, etc.
A hammer and mallet and a markin aue are, ol course, indis-
pensahle.
A ood hrace and set ol at least six hits ol dillerent sizes, ranin
lrom &'( inch up to ! inch will he needed, and an expandin hit
would he an acquisition. These hits may he either American twist
hits, or the ordinary nosed centre -hits.
A small Archimedean drill, with three or-lour drill-hits ol various
sizes.
Three or lour imlets and hradawls ol dillerent sizes.
A screwdriver, and two or three nles ol dillerent shapes and de-
rees ol nneness.
A lue-pot holdin at least a pint ol lue, and two or three lue
hrushes ol-various sizes.
Two or three paint hrushes, one very small and the others me-
dium-sized sash tools.
A wood T-square, not less than c inches lon, a metal-hladed
carpenter's square, q or a inches
ORGAN BUILDING IOR AMATEURS.
A lew screw cramps.
A solderin iron lor metal work, il it is intended to do this work
at home.
A pair ol cuttin pliers, and also a pair ol round nosed pliers ol
small size, lor wire work.
A lew other special tools may he required, which will he de-
scrihed when dealin with the work.
Ol course, it will he understood that these tools need not all he
purchased helore commencin the work, hut only such as are needed
lor the operations actually in hand. The others can he acquired as
the proress ol the work calls lor their aid. It is, however, ahsolutely
necessary that all tools should he ol ood quality and always kept in
thorouh order, lor it is impossihle to work well with had or hlunt
tools.
As reards skill in workmanship, il the would-he oran-huilder
can plane a hoard true, make a ood joint (such as a hutt joint,
dovetail or mortise and tenon), and possesses a eneral knowlede ol
the use ol the various tools mentioned herein, he can, with patience
and perseverance, accomplish nearly all that is set out in these paes.
All wood used must he ol the hest quality, thorouhly sound,
well-seasoned, and lree lrom knots and shakes.
It should he purchased and kept in a warm dry place, as lon pos-
sihle helore usin.
The leather used in oran huildin is white sheep-skin, specially
prepared lor the purpose, and B6 68<A7 L@BE will he suitahle. It can
he procured at any shop where oran requisites are sold, and ener-
ally costs ahout 9. or 9. 6E. a skin. Shoemaker's white leather will
he ol no service whatever.
I now propose to ive such instructions as will enahle amateurs to
huild themselves a really uselul instrument, that may he a source ol
pleasure to themselves and their lriends lor many years to come. In
order to meet the requirements ol all, and with the view ol makin
SPECIIICATIONS.
the instructions as intelliihle as possihle, I shall descrihe a specinc
instrument, and add such inlormation as may he requisite to enahle
the amateur to huild either a smaller or a larer one, as the lenth ol
his purse may permit. But I would here ure upon all intendin
workers that, whatever scheme they may adopt, they should keep to,
and work away at it steadily until all is completed, lor many com-
mence upon work which they have not sulncient patience to carry
out, and consequently, they never have anythin to show lor the time
and money which they have expended.
Amateurs should also consider the time and means at their dis-
posal, helore decidin on the work, and will do well to rememher
that a very small oran, il huilt in spare time, alter ordinary workin
hours, may require months, or even years ol patient application
helore the work can he completed. The reatest pains should he
taken in the construction ol every part, and all should he done as
thouh one's lile depended on the result.
The specincation lor the instrument to he descrihed is as lol-
lows .
. Open Diapason to Tenor C pipes. 8 leet tone.
a. Stopt Diapason, Bass a 8
. Stopt Diapason, Trehle 8
. Ilute (lor Principal) 6
. Keraulophon (small scale, to Tenor C) 8
6. Ilaeolet (lor Iilteenth) 6 a
y. Bourdon (pedals) a 6

Total a8 pipes.
Couplers . octave , reat to pedal.
The whole may he enclosed in a eneral swell. Size ahout 6 leet
6 inches wide, q leet hih, and leet deep.
There will he room lor another stop ol twelve pipes in the hass,
which may he utilised at any time hy the insertion ol a stop ol the
violoncello type.
S
ORGAN BUILDING IOR AMATEURS.
Il the Bourdon were omitted it would reduce the size ol the in-
strument considerahly, or a nice little instrument could he made hy
havin the nrst lour or nve stops only.
Ior a small two-manual instrument, the lollowin would he a
ood specincation .
Great oran .
. Open Diapason to Tenor C pipes. 8 leet tone.
a. Stopt Diapason, Bass a 8
. Principal (Ilute) 6
. Ilaeolet 6 a
Swell oran .
. Liehlich Gedacht 6 8
6. Keraulophon to Tenor C 8
Pedal oran .
y. Bourdon a 6

Total aq pipes.
Couplers . swell to reat unison , swell to reat octave , reat to
pedal.
Same size as No. , hut 6 inches deeper.
A smaller two-manual miht comprise the lollowin stops .
Great oran
Great oran .
. Open Diapason to Tenor C pipes. 8 leet tone.
a. Stopt Diapason, Bass a 8
Swell oran .
. Liehlich Gedacht 6 8
. Ilute (or Principal, small scale)
Couplers . swell to reat unison , swell to reat octave , octave on
reat.
The pedal-Bourdon may, or may not, he added, accordin to the
will ol the amateur. Il it is, a coupler, reat to pedals, would he
needed.
NEW METHOD OI MAKING PIPES. 6
NOTE.Il octave couplers are attached to any ol these orans,
they will he made much more elncient hy carryin each stop on
which they act an octave hiher in the trehle, so that AMA7N note in
the compass ol the key-hoard will he connected with one an octave
hiher when the octave coupler is in action.
The intendin oran-huilder has thus several schemes to choose
lrom , and, as the dimensions ol the soundhoard and all other por-
tions will he lully set out in the succeedin articles, he will he en-
ahled to nnd all the dimensions he will require. The scales lor the
pipes will he the same lor each oran.
It will he noticed that in neither ol the ahove specincations have I
mentioned the materials ol which the pipes are to he made, and my
reason lor not doin so is, that I have worked out a new method ol
makin them, and now propose to ive the amateur the henent ol
my experience. Many who would much like to huild an oran are
deterred lrom doin so hy the reat outlay necessary to purchase the
pipes, or the materials lor makin them , hut it is now open to
anyone, hy lollowin my instructions, to make the whole ol the pipes
required lor Scheme , lor a very much smaller sum than would he
required to purchase the open Diapason alone. That stop, in metal,
would cost ahout L to purchase, a wood stopt Diapason, L8 9. , a
Bourdon, ahout L or La , Principal, metal, L c9. , Keraulophon,
L6 , Ilaeolet, L c9. ,thus runnin up to somethin like Lc lor
the pipes alone. The cost ol the materials lor makin these pipes
would also he somethin considerahle, whilst lor pipes made on my
system, ahout c9. lor each stop will cover the cost, and leave a
marin. The Ilaeolet will cost less than 9.
Many ol my readers will no douht smile incredulously when I
state that the pipes are simply made ol paper , hut I can only assure
them that they answer thorouhly, and I have spent years in makin
various experiments lor perlectin them. The idea, I helieve, is not a
new one, hut I am not aware that it has ever helore heen practically
worked out , and, indeed, it was the ridicule cast on the plan hy
would-he scientists that induced me to persevere with it until I
N
ORGAN BUILDING IOR AMATEURS. y
succeeded. All pipes up to a leet lon may he made ol cartride
paper, hut lor loner pipes stout hrown paper is the hest.
The advantaes I claim lor my system are, that it is very cheap, lar
cheaper, in lact, than any system ordinarily lollowed, as the prices
ahove quoted will show , that the pipes are exceedinly liht, a -
loot stopt Diapason weihin ahout twenty ounces, or an open pipe
the same size lourteen ounces, which will last very lavourahly with
the weiht ol metal or wood in a similar pipe. They are easy to
make, an amateur hein more likely to succeed with these than with
ordinary pipes, as they require hut little skill, and no expensive tools ,
and havin, practically, no join throuhout their lenth, there is no
lon lue joint, as in wood, or soldered joint, as in metal pipes, and,
consequently, no risk ol leakae. They take up only the same room
as metal pipes, thouh they are much stroner, and cannot so easily
he damaed hy rouh knocks, and any lorm ol pipe can he made ,
and last, hut not least, you can try your pipes helore completin
them, and will thus he sure that they will answer.
Belore startin on the pipes, set out the scale lor them in the lol-
lowin manner .on a nicely-planed hoard draw a line leet 6
inches lon, and at riht anles to the top ol this line draw another, a#
inches lon, and join the end ol the short line to the hottom ol the
lon one hy a slopin line , a leet helow the top line draw another
thick line across lrom the lon line to the slopin one, loot helow
that draw another, 6 inches helow that draw another cross line, and
others at inches, $ inch, and % inch, one helow the other. Mark a 1
aainst each ol these cross lines, and 6 inches lrom the hottom set oll
a thick line and mark it with the word mouth. Now divide the
spaces hetween each c into twelve equal parts , the top one will thus
he divided into twelve spaces ol a inches each, the next one into
spaces ol inch each, the next into spaces ol $ inch each, and so on,
each set hein exactly hall the size ol the precedin one. Aainst
each ol these lines write the names ol the notes in the same order as
I have shown them in Ii. , hut I have not heen ahle to show them
all throuh, as the scale is too small to admit ol it. To nnd the size ol
any pipe, you measure lrom the line marked mouth up to the cross
NEW METHOD OI MAKING PIPES. 8
line aainst which is name ol the required note , this ives you the
speakin lenth ol the pipe, and the lenth ol the cross line is the
interior diameter ol it, and so you will proceed to nnd the size ol any
pipe you may require up leet lon.
Belore proceedin larther, it may he as well that I should state
that an open pipe 8 leet lon, which sounds the note CC, is termed
an 8-HAA8 86BA pipe the same term is applied to the whole stop, not
withstandin the lact that the stop may not extend down to CC on
the instrument. Thus hoth the open diapason and the keraulophon
are 8-leet stops, althouh cease at tenor C , hut il carried down to
CC, the lowest note would require an open pipe 8 leet lon. Closed,
or stopt pipes, sound an octave lower than open ones , so the stopt
diapason, soundin CC with its pipe only leet lon, is still termed
an 8-HAA8 86BA 986?.
F6;7OHAA8 86BA 986?9, such as the principal, nutes, etc., sound an oc-
tave ahove the unison, or 8-leet toned stops, and their lonest pipes
on the manual sound-hoard are leet lon, unless they are what are
termed <>7:6B@G stops, in which case, thouh the pipes ive only the
-leet tone, they require to he made as lon as an ordinary pipe
soundin the 8-leet tone.
#P6OHAA8 86BA 986?9 sound two octaves, or a QH8AAB8<, ahove the
unison stops.
.@R8AABOHAA8 86BA 986?9, which appear on the pedal oran only, un-
less in a lare instrument, sound an octave helow the unison, and STO
HAA8 86BA stops sound two octaves helow the unison , hut these latter
stops are only lound in instruments ol the very larest size.
It will he noticed on settin out the scale, that each octave ol
pipes is rouhly speakin, douhle the lenth ol the succeedin octave.
Thus all the pipes lrom CC to B, are douhle the lenth ol those lrom
tenor C to the B ahove. It will also he ohserved, that in the -leet
octave, each pipe is a inches shorter than the precedin note, in the
a-leet octave, each pipe is inch shorter than the one precedin it,
and so on up to the smallest pipe.
ORGAN BUILDING IOR AMATEURS. q
It will he hest lor the amateur to make a small pipe or two, lor
experiment, helore he starts on the set lor the oran. A convenient
size to commence with will he the G
a
in the trehle ol the open
diapason. This pipe, as you will nnd lrom the scale, is 8$ inches
speakin lenth, and ahout )* inch diameter. You will require a
mandrel to lorm it upon, and my method ol makin this is cheap and
simple, viz., take a sheet ol stout, smooth paper, a inches wide, and
roil it up tihtly until it is )* inch diameter (the size required lor our
pipe), takin care that you roll it straiht, and have the ends square,
or your pipe will not he a true cylinder, hut slihtly conical. When
you have rolled it to the riht size, lue the ede down smoothly, and
let it dry, which will only take a lew minutes. Il you have used a
sulncient lenth ol paper, you will now have a perlectly round
straiht nrm mandrel to work on. I may say that an ordinary round
lead pencil will answer very well lor startin the rollin up ol the
paper. Now cut a piece ol nice smooth cartride piper q inches
wide, and lon enouh to o lour times round the mandrel, which
will take ahout q inches. Cut the sides ol the paper perlectly square,
and then roll it once round the mandrel and mark that distance hy a
pencil line, take it oll the mandrel, and then with a hrush lull ol hot,
thin lue, o over all the rest ol the paper up to the pencil line ,
>DD6P 8<A CD;A > :@B;8A 67 96 86 96>L @B >BE 8<A ?>?A7 86 987A8G<, and
then carelully roll it round the mandrel, ruhhin it well down with
the nners, or with a small round stick (the lead pencil will do very
well) as you roll it up. When it is all rolled up, roll it hetween your
hands on the tahle, like a cook rollin out douh, and ruh the joint
well down, and also ruh the pipe all over with the round stick. Slip
it oll the mandrel (there hein no lue on the nrst turn cannot stick
to it), and stand it up on end to dry, and it will he a tuhe q inches
lon, )* inch internal diameter perlectly straiht and smooth inside
and out. All this can he done in less time than it takes me to write
the directions.
While the tuhe is dryin, you may make the conical portion lor
the loot, this hein lormed ol a piece ol paper shaped as in Ii. ,
ahout q inches wide and 8 inches deep. Commence rollin it lrom
the top corner as shown hy the dotted lines in the sketch, and when
NEW METHOD OI MAKING PIPES. c
rolled up it will assume a conical shape ol any diameter you may like
to make it. Unroll it, ive it a coat cl thin lue, and P<AB @8 <>9 <>E
8@:A 86 987A8G<, roll it up aain, ruhhin it well down, inside and out,
with a pointed stick to make each layer adhere thorouhly. When
this is completed you will have a conical tuhe like Ii. , runnin
almost to a point at one end, and irreular at the top. The outside
join should he a straiht line riht down the cone, not windin round
it , the paper can he cut so as to ensure this just helore you nnish
rollin it up. When this is dry, hoth the tuhe and the cone must he
painted or varnished inside.
Thouh it may seem rather a dilncult joh to paint the inside ol so
small a tuhe, it is, however, quickly and easily accomplished hy tyin
a piece ol spone on to the end ol a thin cane or wire, so that it
lorms a kind ol mop that will just o into the pipe , dip this in the
paint and work it up and down the inside ol the pipe two or three
times, and the joh is done in less than a tenth ol the time it would.
take with a hrush, and securin a much smoother coat ol paint. The
cone may he painted with a smaller mop, or a nne hrush.
The paint must he allowed to et thorouhly dry and then you
may trim oll the top and hottom ol the pipe with a pair ol small
pointed scissors, and trim oll the top ol the cone in the same way till
it is exactly the same diameter as the tuhe, then ruh the ends ol the
pipe and the top ol the cone perlectly level on a piece ol lass-paper
stretched over a hlock ol wood covered with cork. Cut out a nat
piece ol mahoany or cedar &+, inch thick to the shape shown in Ii. ,
the straiht part hein two-ninths ol the circumlerence , the top and
hottom ede ol this straiht part should he slihtly rounded oll with
nne lass-paper. This circular piece, which is called the lanuid,
should just nt the hottom ol the tuhe on which you may now lay it,
and mark where the ends ol the straiht part come, then cut a three-
cornered piece ol that width, and ahout inch lon out ol the tuhe
immediately over it, as shown in Ii. 6. A similar piece must now he
cut out ol the lront ol the cone, hut the ap must he slihtly nar-
rower, so that, when it is placed aainst the end ol the tuhe, the lront
ol the cone will project slihtly heyond it, to allow lor the windway.
ORGAN BUILDING IOR AMATEURS.
A piece ol thin mahoany, or cedar, shaped as in Ii. , is cut to nt on
the top ol the cone. Lay the tuhe on a piece ol lass-paper so that
the part where the piece is cut out lays nat on the paper, and ruh it
down level, and proceed in the same way with the cone. Cut out
two pieces ol wood like Iis. y and 8 , the nrst piece is chamlered on
the lront to lorm the upper lip, and the other is just rounded oll at
the top edes to lorm the lower lip. Glue the lanuid on to the
hottom ol the tuhe, and the under lanuid on to the top ol the cone ,
when dry you may hind on the upper and lower lips in- their proper
position with a piece ol narrow tape. The heiht ol the mouth is
ahout a quarter ol the diameter ol the openin.
You may now place the cone and the pipe toether in their
proper position, leavin a narrow windway hetween the straiht ede
ol the lanuid and the lower lip , hold it in that position and hlow
ently throuh the pointed end ol the cone, and you will he re-
warded hy a musical note. Il the note is not quite satislactory, the
upper lip may want shiltin a little hiher or lower, or the lower lip
may require a little shiltin. The top ol the lower lip should he level
with the top ol the lanuid, or hut very slihtly helow it. The
windway should he ahout wide enouh lor a piece ol thin playin
card to pass. On the lront ede ol the lanuid, nne nicks should he
made in a slantin direction with a nne penknile . ahout twenty to
the inch lor this pipethis is the voicin, lull directions in reard to
which will he lound in the chapter on voicin and tunin. Mark on
the pipe the heiht ol the mouth, then take oll the lips, lue them
and hind them in their places with tape. Even in the matter ol
hindin on, there is a riht and a wron way , the proper way hein
to hind with hoth ends ol the tape, so that it crosses down the centre
ol the lip, you will then et the edes ol the lip parallel with the ede
ol the lanuid. This is a point to he ained, as, il it is not parallel, the
note will he laulty, either squeakin or chilnn, as it is termed, helore
it speaks the proper note. Il it is satislactory you may now lue the
loot on to the tuhe and stand it up, and when dry, ruh down the
sides ol the lips and round the joint ol the lanuids with lass-paper
to make it look neat. Cut a piece ol lazed dress-linin as in Ii. a
(the marks show where it is to he cut to make it lay even on the
NEW METHOD OI MAKING PIPES. a
cone), and lue it round the joint ol the pipe, to strenthen it. There
may he a little piece ol the pipe projectin on each side ol the
mouth, which should he taken oll with a sharp penknile. This is the
smallest pipe that will require ears,
which are simply pieces ol veneer
shaped as at A, in Iis. , and ,
and lued on to the pipe aainst the
edes ol the lips, so that no wind may
he lost. They will want chamlerin on the ede
where they are lued to the pipe, to make them
nt on , this may he done with lass-paper.
Cut oll the hottom ol the loot to the size re-
quired, ahout 6 inches will he lon enouh, and
chamler it oll at the hottom ahout ! ol an inch
with a sharp knile. This chamler has now to he
coned in, just the same as metal pipes are, a
metal cone hein used lor them , hut the ama-
teur need not lay out y95 6E, in huyin a metal
cone, as a common china e-cup, costin a
penny, will answer the purpose equally as well.
The under part ol the loot will do to cone small
pipes, and the cup itsell will he used lor lare
ones. You have merely to wet the chamlered
part with your lips, place the loot ol the e-cup
on it, and work it ently round with your hands
till it is coned in sulnciently. The hole should
come in the centre ol the conin, and is ahout &+,
ol an inch in diameter lor this pipe , it may he
made quite round hy insertin the point ol a
lead pencil with a sliht screwin motion.
When dry, the conin is quite hard, hut the hole
can he enlared with the pencil, or closed with
the conin cup, as may he required, to admit the
proper amount ol wind. Trim down the top ol
the pipe with the scissors until it speaks rather too sharp a note ,
then make a short piece ol tuhe ahout inch lon that will just nt on
Ii. a.The Linen Band.
Ii. .Section ol
Pipe (lull size).
ORGAN BUILDING IOR AMATEURS.
the pipe, and slide easily up and down. This is the tunin piece ,
raisin it will natten, and lowerin it will sharpen the tone. The
appearance ol the pipe will he improved il you chamler oll the top
ede, and also the top and hottom edes ol the tunin cap. Give the
pipe and slider two or three coats ol oil paint to preserve it, and it
will now he nnished.
The experience
ained in makin this
pipe will he very
uselul, and you will
very soon acquire the
method ol manipula-
tion, so that you can
o to work with
certainty. Makin a
sinle pipe takes some
time, as you have to
wait ahout lor the
parts to dry, hut when
you commence on the
sets ol pipes required
lor the oran, you will
nnd that no time need
he lost.
The nrst thin you
will require to make
will he several man-
drels, say one lor
every lourth pipe ,
make them consid-
erahly loner than the pipe to he lormed on them, lor one mandrel
may he used lor more than one pipe. It is a maxim in oran huildin,
that each stop should he ol a dillerent scale, hut it will only he
necessary to make one scale lor these pipes, except the hourdon and
the lowest octave ol the stopt diapason.
Ii. .Section ol Pipe
with inverted mouth.
Ii. .Section ol Stopt
Diapason shown in Ii. 6.
NEW METHOD OI MAKING PIPES.
The scale as it stands is lor the open diapason, the stopt diapason
trehle will he one scale larer, that is the C ol that stop will he made
on the B mandrel ol the open pipe, and so on. The nute, or princi-
pal, will he one scale smaller than the open diapason, the naeolet
may he two scales smaller, while the keraulophon will he six scales
smaller , thus we may proceed with the tuhes lor all the pipes si-
multaneously. Havin cut the sheets ol paper to the necessary size,
>DD6P@BC 9;HQG@AB8 DABC8< @B A>G< ?@?A 86 G;8 6HH 8<A 8;B@BCO?@AGA9 as
the piece cut oll one pipe will nt on to a smaller one and thus save
havin to make separate pieces mark the distance ol one turn
round the mandrel hy a pencil line on all ol them, and mark them
also with the name ol the note ol the pipe they are intended lor.
Suppose you start on 6 inch C, open diapason, you lue that sheet
and lay it aside, lue another sheet lor 6$ inch B lor the, nute, and
another lor % inch, Cs. stopt diapason. Now take up your nrst sheet
and roll it round the mandrel, proceedin in the same way as with
the experimental pipe , when nnished draw it oll and stand it up to
dry, roll up the second sheet, and slip that oll, then proceed with the
third. The reason lor doin three sheets at a time is that it allows just
sulncient time lor the paper to stretch and the lue to et riht lor
rollin up. You then lue three more sheets, viz., y inch As. na-
eolet, the q inch Is. ol the keraulophon, and one ol the sheets lor
another mandrel, thus you can keep on makin these tuhes at the
rate ol twenty or thirty an hour when you et used to it, and have all
the stops in hand simultaneously. Mark each pipe in ink with the
name ol the note and the stop it helons to, so that you may he ahle
to keep each stop separate. When you have made all the pipes you
require on one mandrel, roll more paper round it and lue the ede
down, to hrin it up to the proper size ol the next pipe, and so
proceed till you have made all the tuhes. Use cartride paper lor all
pipes up to a leet lon, usin stouter paper lor the larer ones, or else
have nve thicknesses instead ol lour. All pipes ahove a leet lon
should he made ol stout hrown paper, ol which an excellent sort lor
our purpose is sold lor layin under carpets , it runs leet 6 inches
and someies leet wide, and is continuous , the price at all shops is
s. per dozen yards, hut at lare, or wholesale shops, it may he pur-
ORGAN BUILDING IOR AMATEURS.
chased much cheaper the -leet pipes should have nve or six thick-
nesses and the larer hourdons seven or eiht thicknesses. It will he
more convenient il you make the lare hourdons in two lenths, and
then join them in the centre, coverin the joint with a hand ol linen
or thin American cloth, to strenthen it, or prelerahly luin extra
thickness or two ol paper over the whole lenth ol the pipe. The
hourdon CCC is 8 leet lon and % inches diameter, the smallest is a
leet lon and - inch diameter. The stopt diapason CC is to he !
inch diameter, and tenor C % inch diameter. I apprehend that no
dilnculty will he experienced in settin out the scales lor these
similar to the scale previously made.
Havin completed the tuhes we may now proceed with the cones
lor the leet, and may use up the paper in the tuhe mandrels lor that
purpose. No mandrel will he required lor the cones lor pipes less
than inch diameter, as you can roll the paper up without hein
particular as to the size, lor they are sure to nt some pipe, and can he
cut oll at either end to the requisite size. Six inches is lon enouh
lor all pipes up to 8 inches lon, hut lor pipes ahove that lenth
they should radually increase till they are ahout a inches lon lor a
-loot pipe. The lenth ol loot makes no dillerence in the tone, so it
is a mere matter ol convenience and appearance. Ior the cones ol
the larer pipes you had hetter make two or three mandrels ahout
inches lon and ol dillerent diameters. Make them in the same way
as the cones, only, very much stouter. The cones should he stouter
than the pipes as they have to hear all the weiht, and are exposed to
a ood deal ol wear. Havin completed the cones you may next
proceed to paint the inside ol hoth them and the tuhes, startin with
the larest, as you can trim your spone mop smaller so as to suit the
smaller pipes. While the paint is dryin you can prepare the other
parts. The stoppers lor the stopt diapason and hourdon pipes may
he made ol wood shaped as in Ii. c, covered with leather round
the lower ede, so as to nt tihtly inside the pipe. I preler to make a
dillerent style ol coverin or stopper as lollows .Make a short
lenth ol tuhe the same as lor the slidin piece lor tunin the open
pipes, lue a piece ol stout card on the top ol this, thus lormin a
hox or lid. Glue a strip ol solt leather round the inside, havin
NEW METHOD OI MAKING PIPES. 6
previously pared down the edes ol the leather , this cap is to nt
tihtly on the outside ol the pipe like a lid. The leather should he
ruhhed with a mixture ol tallow and hlack lead to
make it slip easily, lor it should not nt too tihtly
to he moved, as the pipe is tuned hy movin it up
or down. This cap is much lihter than the wood
stopper, easier to make, and there is no daner ol
it slippin down, as Stoppers sometimes do when
there is a sudden chane in temperature. The caps
should nt loosely on the Pipes at nrst so as to allow
lor three coats ol paint on the pipe, when they
should nt perlectly air-tiht. As it is hest to put
the stopt pipes toether with caps on, they may he
temporarily ntted hy wrappin two or three
thicknesses ol paper round the pipe.
The caps ol the stopt diapason should he 6
inches lon lor CC, and $ inch lon lor the smallest
G. The tunin caps ol the keraulophon are not
closed at the top, they should he 6 inches lon lor
tenor C, and $ inches lon lor the smallest G. In
the centre ol the side ol the cap, a distance ol one
diameter lrom the top, there is a round hole " inch
in diameter lor tenor C pipe, and ahout &+( inch lor
top G. The hest way to make this hole is hy a
taper hit ol such size that when it is hored throuh
the cap so that the point just touches the lurther
side ol it, the hole in tenor C is " inch in diameter,
and as each cap ets smaller, the pushin the hit
throuh so that it touches the lurther side, will
cause the hole to diminish reularly. A sharp
pointed stick will do instead ol a hit, as the hurr
could he cleared oll with a hot wire. The small scale hih mouth,
and the hole in the slidin cap ol the keraulophon cause it to ive a
rich, thouh quiet, striny tone, which is very uselul in solo passaes.
Ii. 6.Iront view
ol Stopt Diapason,
showin Arched
Upper Lip.
ORGAN BUILDING IOR AMATEURS. y
The nute and naeolet pipes are made with the upper lip turned
so that the chamler comes on the inside ol the pipe, and the lanuid
is sloped downwards on the lront ede, as shown in Ii. . This
causes it to ive a solt quiet tone. The nute should he solter in tone
than the diapason, and the naeolet should he solter than the nute.
The stopt diapason is made with a hih mouth, and the upper lip is
cut slihtly circular, the lower lip may he a little helow the top ede
ol the lanuid.
The approximate lenths ol the pipes lrom the mouth up to the
top, and the sizes ol the mouths lor the several stops are as lol-
lows .
Approximate
Width ol Mouth. Heiht ol Mouth. Lenth ol
Lonest Pipe.
Lenth ol
Shortest Pipe.
Bourdon................... One-lourth ol the
circumlerence
One-third ol
its width
8 lt a lt
Stopt Diapason.... One-lourth One-third lt a. in.
Open Diapason.... Two-ninths One-lourth lt ! in.
Keraulophon......... One-nlth One-third lt ! in.
Ilute.......................... One-nlth One-nlth lt a. in.
Ilaeolet.................. One-nlth One-sixth a lt &+( in.
The sizes ol the holes at the hottom ol the coned leet are ahout
as iven hereunder, hut the pressure ol wind and the voicin allect
the sizes considerahly, and they may have to he a little larer or a
little smaller accordin to circumstances.
CCC. CC. Tenor C. Middle C. Top G.
Bourdon.............................. - in. # in. " in. . .
Stopt Diapason............... . # in. " in. ! in. . in.
Open Diapason............... . $ in. " in. ! in. . in.
Keraulophon.................... . " in. &/( in. &'( in. . in.
Ilute..................................... . " in. &/( in. &'( in. . in.
Ilaeolet............................. . &/( in. ! in. . in. &+( in.
The Liehlich Gedacht is simply a stopt diapason ol the same
scale as the principal, hut with a straiht upper lip, and the lower lip
slihtly helow the upper ede ol the lanuid. The lanuid increases
in thickness with the size ol the pipe, that ol a loot pipe should he
! inch thick. The same remark applies to the lips, which should
increase in size and thickness with the size ol the pipe. The upper
NEW METHOD OI MAKING PIPES. 8
lip ol the CC stopt diapason should he nearly 0 inch thick at the
thinnest ede. The lips can he expeditiously cut out ol a piece ol
thin wood, hy markin it out as shown in Ii. y, and cuttin thouh
the marks with a tenon saw. The very hest wood you can use lor the
lanuids and lips (except the smallest,
which are simply veneer) is ciar-hox
wood. Ciar hoxes can he purchased lor
twopence or threepence at most tohac-
conists or puhlic houses, and many
shopkeepers will ive them away to their customers. The lanuids ol
the larer pipes may he ntted into the ends ol the tuhes instead ol
hein simply lued on to them.
Havin prepared a quantity ol lanuids, lips, etc., lue them on,
havin previously cut out the portion ol the tuhe and cone where
lips come.
Ahout a dozen pipes will he lound a ood umher to have in hand
at one time lor puttin toether.
The windway lor the larest hourdon is nearly . inch wide, lor a
CC stopt pipe &+( inch wide, and radually smaller lor each succeed-
in pipe. Stopt pipes require a larer windway than Open pipes, as
the mouths are cut hiher and the upper lips are much thicker. The
voicin nicks are nearly . inch apart in a loot pipe, hut et closer
and smaller as the pipe diminishes in size, until in the smallest pipes
they are scarcely perceptihle scratches very close toether. They may
he made with a very nne tunin nle, or a small penknile. Ior a loud
tone, the nicks should he lew and deep, lor a solt, sweet tone, they
must he very nne and close toether, the hurrs hein taken oll hy a
sliht touch with a piece ol nne lass-paper. The upper chamler
should not he nicked. Wherever the wind passes there should he no
sharp edes or it will cause a hissin noise, therelore, the top and
hottom edes ol the lanuid, the edes ol the lower lip, and the lront
ede ol the upper lip should he slihtly rounded oll hut the inner
ede ol the top lip should he lelt square.
Ii. y.Method ol Cuttin out
the Lips.
ORGAN BUILDING IOR AMATEURS. q
Il it should happen that when a pipe is nnished the windway is
too narrow, it may enerally he set riht hy passin the thin hlade ol
a penknile nat down hetween the lip and the ede ol the lanuid, hut
il this is not sulncient, cut a slip ol nne lass-paper and insert that,
movin it ently up and down, so as to take a very little oll either the
ede ol the lanuid or the inner
ede ol the lip, whichever may he
required, and then carelully touch
up the voicin. Ior cuttin the
lips a little hiher, and touchin
up the pipes enerally, you will
nnd the lollowin tool very
handy, and should make nve or
six ol dillerent sizes .a thin slip
ol wood, or veneer, say inch wide at one end, and $ inch wide at the
other, covered on one side with very nne lass-paper and on the
other with some a little coarser. You will thus have lour nles in one.
Another handy little appliance is shown at Ii. 8 , it is a hlock ol
wood, or 6 inches lon, inches wide, and $ inches thick, covered
on the hottom with a nat piece ol cork. A piece ol lass-paper can
he stretched over this, and rasped in the hand, and may then he
used to smooth oll the ends ol the pipes, the edes ol the lips, and
any small chamlerin. You will have this hlock in requisition at all
staes ol the work.
The pipes, caps, and tunin pieces, should have three coats ol oil
colour, a little varnish hein mixed with the last coat, and it will he
lound a ood plan to paint each stop a dillerent colour, as any stop
can then he picked out at once.
Write the name ol the note, and the stop, on the hack ol each
pipe, usin ordinary ink and a Waverley or Pickwick pen, as the
points will not scratch the paint. Breathe on the place and pass the
nner over it, the ink will then now as nicely as on writin paper.
The paintin or varnishin ol the pipes preserves them lrom the
damp, and improves hoth their tone and appearance.
Ii. 8.Block covered with Cork lor
usin with Glass Paper.
NEW METHOD OI MAKING PIPES. ac
The lollowin points should he strictly adhered to, viz., all pipes
ahove a inches lon should he allowed to dry on the mandrel, or
they may he apt to cast a little, which will not improve their appear-
ance , the loot to he perlectly straiht with the pipe, the lips to he
quite parallel with the ede ol the lanuid and with each other, the
nicks lor the voicin to he even and reular, and the caps ol the stopt
pipes to nt perlectly air-tiht.
a
CHAPTER II.
!&&, 1"1(.5
NOW proceed to descrihe the process lor makin wood
pipesso that the amateur may he ahle to place them in his
oran lor use either hy themselves or in conjunction with the
paper pipes descrihed in the previous chapter. I would remark,
however, that every variety ol tone required may he ohtained lrom
the paper pipes, whilst the wood pipes allord hut a limited rane ol
tone. The Keraulophon stop, lor instance, cannot well he made ol
wood, hut is very successlul in paper.
As with the other pipes, we shall, ol course, require a scale to
work lrom, only it will he necessary to set out a lresh one lor each
stop. Draw the line on a hoard leet 6 inches lon, and divide it out
exactly as descrihed in the last chapter, hut as wood pipes are not
round hut ohlon in plan, two diameters are required lor each pipe,
instead ol only one as in round pipes. The size ol the larest stopt
diapason is $ inches deep hy a# inches wide, so you set oll those
distances on the topmost cross-line, and draw the slopin lines lrom
them down to the point 6 inches helow the mouth, as shown in the
sketch, Ii. q. By measurin in just the same way as helore de-
scrihed, you will he ahle to ohtain the lenth, width, and depth ol
each pipe. I have only shown the larest octave on the sketch, as I
think you will have no dilnculty now in makin a scale lor any sized
stop you may wish lor.
The six larest pipes ol the stopt diapason will he made ol % inch
pine, and the others will he raduated in thickness till the smallest is
only &'( inch thick. You need only take the rouhness oll the side ol
the wood which is to lorm the outside ol the pipe, lor it is hest to
plane them up when you have put them all toether, as you can
make them look nice, and also raduate the thickness ol the wood in
W
!
WOOD PIPES. aa
reular proportion to the size ol the pipe. Let all the wood he ol the
hest quality and lree lrom knots or shakes, as knots are almost sure to
loosen some time or other and thus spoil your work, perhaps when
you are least ahle to remedy it. Keep your wood hy you as lon as
possihle helore usin it, so as to ensure its hein thorouhly well
seasoned. Iirst prepare some wood lor the hlocks ol your pipes, hy
planin up some lenths ol pine ahout a leet lon, and luin a piece
ol " inch mahoany on one side ol them. The scantlins ol these
pieces will he indicated hy the diameters ol the pipes lor which they
are to lorm the hlocks. Plane the nrst piece down to the size re-
quired lor the larest pipe, viz., $ inches hy a# inches, the mahoany
lacin hein on one ol the narrow sides, and cut oll a piece inches
lon , dress the remainder down to the size ol the next pipe, hut do
not touch the mahoany side aain, and cut oll inches lor that one ,
dress the remainder down lor the next sized hlock, and cut that oll,
and so keep on till you have cut oll all your hlocks. The nrst twelve
will he inches lon, the next twelve inches, the next a$ inches, the
rest ahout a inches, and these proportions may he used lor all the
pipes in each stop, as the lenth ol the hlock is not a very material
point provided it is lon enouh. Now shape the hlock as shown in
Ii. ac, hy cuttin a ap with a tenon saw throuh the mahoany
lacin into the hlock, keepin the same proportions lor each hlock,
and usin a chisel to take out the piece. The slopin part should he
cut up to within ahout ! inch ol the top ede, hut he extremely
carelul not to damae the ede. The openin shown in the hottom is
a round hole, which will he hored alter the pipe is put toether, and
the loot will he inserted in it. When you have ot a dozen or so ol
these hlocks ready, et out the wood lor the sides ol the pipes,
rememherin that the sides are the deepest measurement ol the
hlock, and also that the sides and hacks must he lon enouh to come
down to the hottom ol the hlock as the scale lenth does not include
this. Alter planin them true ive them all a coat ol very thin hot
lue on the inside, to stop all the pores, and, when dry, lue the
hlock in hetween them as shown in Ii. a. It will he well to pre-
serve the pieces you cut out ol the hlocks, and lue them hetween
the sides at the top ol the pipe, and you will thus have them quite
ORGAN BUILDING IOR AMATEURS. a
parallel. The pieces lued at the top will he cut out when trimmin
down. Il you cannot et these pieces out ol the hlocks without
hreakin them up, you must cut a slip the same width and use that
when luin up the pipes. While this is dryin prepare the hacks,
treatin them with thin lue the same as the sides, and then lue
them on to the sides. It will he well to allow hoth the hacks and
lronts to lap over ahout . inch on each side, so that the dents made
when you hind the pipes up with stron tape or strin to secure the
lue joints may he no detriment, as they can he planed oll alterwards.
Now prepare the lrontswhich only extend down to the top ol
the hlockand cut the chamler lor the upper lip, and the openin
lor the mouth, as shown in Ii. . It is a very ood rule to cut the
chamler as hih as it is wide, hut the lips had hetter not he cut too
hih nor too thin at nrst, as the heiht ol the mouth will have to he
reulated when you are enaed in voicin and tunin, instructions
lor which will he iven in a suhsequent chapter. All dimensions lor
the heihts ol the mouths, the widths ol the windways, the holes in
the hlocks and leetin lact, every size except the diameters ol the
pipes, will he the same lor the respective stops as those iven in the
last chapter lor the paper pipes, so there will he no need lor me to
recapitulate them here. The sizes iven lor the holes in the leet ol
the smaller pipes in pae y must he considered as only approxi-
mately correct, as they may require to he coned in much smaller in
some instances. In the wood pipes it is especially necessary that the
hole should he lare enouh to allow plenty ol wind to pass. Il it
should he too lare, a small wood plu is inserted at the hottom to
stop oll a little ol the wind, hut it would he awkward to remedy il
the hole was too small, as it would entail the enlarement ol it riht
throuh the lenth ol the loot. You will nnd the small American
planes, which are made ol iron, very uselul lor smoothin the cham-
lers, etc.
Belore luin on the lronts or hacks he sure that they will lay
perlectly nat on the edes ol the sides, and in order to secure this it is
hest to shoot the edes with the plane alter the hlocks are lued in.
The lront and hack surlaces ol the hlocks should coincide with the
WOOD PIPES. a
lines ol the lront and hack edes ol the sides. Glue on the lronts, and
hind them up tihtly with stout ape or strin, and then leave them to
dry while you prepare the caps. These caps are the pieces ol wood
which cover the aps in the lront ol the hlocks. All the caps should
he made ol mahoany, those lor the stopt diapason hein simply nat
pieces the same thickness as the lronts ol the pipes. The windway in
the hlock (on the top lront ede) should he made with a nat nle , do
not make it too deep, hut leave the nnal touchin up lor the time
when you are tunin. You may now with a centre-hit hore the holes
in the centre ol the hottom ol the hlocks to receive the leet, which
are simply round pieces ol wood ahout 6 inches lon, with a hole
throuh them ol the size required. They can he purchased ready
made at a very cheap rate, hut il you have a lathe they may he made
at home.
Next prepare the stoppers, or tompions, which are shaped as in
Ii. a, and covered with solt sheepskin, so that they will just nt into
the top ol the pipes so as to close them in quite air-tiht. The stop-
pers must not, however, nt so tihtly as to prevent their hein moved
up and down. The leather is to he lued on the rained side, and this
must he nrst well ruhhed over with lass-paper to take oll all the
smoothness, or the lue will not hold. A mixture ol tallow and
hlack-lead should he ruhhed on to the outside ol the leather when
the stoppers are completed, and they will then slip up and down
easily, hut he sure that they are perlectly airtiht. Let no one per-
suade you to make stoppers ol a piece ol hoard with a handle stuck
in the middle, as in consequence ol the hearin surlace hein so small
they slip askew and lorce the seams ol the pipes open, thus ruinin
them. The stoppers should have, at least, a inches in depth ol hear-
in surlace. I may say that hrads may he used in addition to lue lor
puttin the larer pipes toether, hut he carelul not to drive any nails
into the hlocks or you will ruin your hits when horin the holes lor
the leet. The leet should not he lued in till it is time to plant them
in their places, as you will then he ahle to reulate them so as to
ensure the pipes hein upriht. Iile no notches on the edes ol the
hlocks, hut leave them quite smooth.
ORGAN BUILDING IOR AMATEURS. a
The hourdon is simply a stopt diapason, and is made in exactly
the same way. The larest pipes may, il you like, he made with
lanuids instead ol a solid hlock, hy cuttin two pieces ol wood, and
nttin them into the pipe as shown in Ii. a, and they may he
secured with lue, and small hrads. The larest pipe CCC, which
may he made ol -inch pine, is 8 leet lon, % inches deep, and #
inches wide , the smallest is two leet lon, a" inches deep, and a
inches wide. The hourdons should also he lurnished with ears as
shown at E in Ii. a. You must not he disappointed with the hour-
dons il they do not appear to sound very loud. Close to the oran a
mere rush ol wind miht he heard, hut some distance away the
sound would he overpowerin, in the next house, or two or three
houses oll, it would, most likely, he voted a nuisance. I may state,
however, in order to prevent misapprehension, that it is not advis-
ahle to have a separate pedal oran lor a room less than 6 leet
square. An additional hass stop on the manual, to he used in lieu ol a
6-leet pedal stop, will he descrihed in the next chapter.
The Liehlich Gedacht (German, lovely stopped pipe) is simply a
stopt diapason ol the same scale as the open diapason. The hlock is
cut out as shown in Ii. a6, and the mahoany lacin projects % inch
ahove it lor CC, and ahout . inch lor the smallest. This stop is
descrihed to he used in the swell oran ol the two-manual instru-
ment, hut it may he suhstituted lor the stopt diapason ol the sinle
manual lrom tenor C upwards. The stoppers are made in the same
way as lor the stopt diapason. The cap is hollowed out, as shown at
c in Ii. a6, and Ii. c is an inside view ol a similar cap. The top ol
the cap should he slihtly helow the ede ol the mahoany lacin,
ahout . inch in the larest and 1+2 inch in the smallest.
We now come to the open diapason, which is the chiel stop in
the instrument, hut in our small instrument it is only carried down to
tenor C, which, however, hein an open pipe, is leet lon, the same
as the CC stopt pipe , the width ol it is a$ inches and the depth a%
inches. It has a straiht hlock with merely a throat cut in it, as
shown in Ii. ay , the cap c is cut out as there shown, and another
view ol it is iven in Ii. a. The upper part ol this hollow should
WOOD PIPES. a6
not he made with the chisel, hut with a nat nle as it is very easy to
make too deep a windway, and then you would have to reduce the
thickness ol the cap hy ruhhin it on lass-paper in order to remedy
the delect. All hollow caps should he slihtly thicker than the lronts
ol the pipes, and project helow the hlock so as to allow ol screwin
them on without splittin them. Three, or at most
lour, small screws to each cap are all that should
he required, and the cap should nt so nicely that
no wind can escape except throuh the windway.
We next come to the nutes top, which is made
in a rather dillerent manner, as it has what is
termed an inverted mouth, that is the chamlered
side ol the lip is turned to the inside ol the pipe so
that the lront would appear quite plain all the way
down, with merely the mouth cut in it. You must not plane the
lront ol this stop alter it is put toether, or you will spoil it, all
planin lor the lront must he done helore it is lued on. This pipe
will require two caps, the inner one hein merely a nat piece ol
mahoany, as in Ii. aq, the exact thickness ol the lront ol the pipe,
and havin a round hole hored opposite to the throat, and counter-
sunk on the outside. This cap projects ahove the ede ol the hlock
exactly the same heiht as does the mahoany lacin in the Liehlich
Gedacht. The outer cap is also hollowed out
exactly in the same way as lor that stop, hut
should he level with the top ede ol the inner
cap. The scale lor CC is a$ inches deep and a!
inches wide.
Another stop, which may he made ol paper
or wood, and is called the Gemshorn (German,
oat's horn) may he suhstituted lor the nute. It
ives a heautilul, slihtly striny tone, not quite
so powerlul as the nute, hut more penetratin, and is much used in
small orans as a suhstitute lor the principal. It is conical in shape,
the diameter at the mouth hein the same as in the nute, hut at the
top it is only one-third ol that diameter. Ol course it is rather more
Ii. aq.Iront View
ol Inner Cap.
Ii. c.View ol Inside
ol Outer Cap ol Ilute.
ORGAN BUILDING IOR AMATEURS. ay
trouhle to make than the straiht pipes on account ol the necessity ol
preservin the proper proportions. Il made in paper, one mandrel lor
every three pipes will he all that is necessary as you can cut the pipes
down at either end to et them to the proper size, and you would
make them in much the same way as you make the conical leet, only
takin care to have the inside join in a straiht line down the pipe.
The mouth is cut up one-third ol its diameter, and, il made ol wood,
the hlock and cap may he like either the nute or open diapason,
which ever you may desire (see Ii. ).
The keraulophon, as I have already stated, should
not he made ol wood.
The naeolet stop is made with a hlock shaped as
in Ii. , and has an inverted mouth like the nute.
The larest pipe is only a leet lon and the scale is "
inch deep hy &'( inch wide. This stop will need reat
care in makin as the pipes run so very small in the
trehle, and you must he very carelul not to let it he
too loud and shrill. Il you can possihly allord it,
make these pipes entirely ol cedar or mahoany. The
holes throuh the leet are very small, so the hest way
will he to lue a disc ol thin mahoany on the hot-
tom ol the loot so as to close it up entirely, and then drill a very nne
hole throuh it. This, ol course, applies only
to the pipes ol the smaller octaves.
The thickness ol the wood will he nearly
the same lor the same sized pipes ol any stop,
hut you may allow stopt pipes to run thicker
than open ones, as they ive a note a octave
lower. The rule is that the thicker the wood
the luller and rounder is the tone. Open
pipes are tuned hy a lid ol solt tin or zinc
which is hent down and let into a saw cut
made in the thickness ol the hack ol the pipe. This lid should he
rather larer than the top ol the pipe, hut should never he shut riht
down , raisin it sharpens and closin it lowers the tone.
Ii. .Section
ol Lower Part
ol Ilaeolet.
Ii. a.View ol Inside
Cap lor Open Diapason.
WOOD PIPES. a8
The pipes are all to he made accordin to the
lenths iven in the scale, with the addition ol the
lenth ol the hlock. They will all he slihtly loner
than the tone speakin lenth, hut this is necessary in
order to allow lor the stoppers in the stopt pipes, and
lor cuttin down to the riht note in the open pipes.
The same remarks apply to the scale lenths ol the
other pipes. When trimmin the pipes down only
very narrow pieces should he taken oll with the
tenon saw, lor you can always take oll more il re-
quired, hut it hecomes an awkward matter to remedy
il you cut the pipe too short. The scales ol all the
pipes descrihed are small scales, suitahle lor chamher
orans. Ior a church oran the scales would he much
larer.
The lips ol the lare hourdons may he made ol
mahoany and tonued on to the lronts, as shown in
Ii. a, which is to a scale ol $ inches to the loot.
All the 9AG8@6B9 in this chapter, with the exception
ol Ii. a, are to a scale ol inches to the loot, or one
quarter ol the lull size. They represent the larest
pipe in each stop. The sizes ol the throats in the
hlocks and the sinkins in the caps may he taken lrom
these sections, and should he radually lessened lor
each successive pipe, preservin ahout, the same
proportions to the size ol the hlock. It is, however,
not requisite that the dimensions ol the throat should he set out with
mathematical nicety.
The pipes, when completed, should he carelully packed away in a
dry place in a room where the temperature is ahout the same as that
in which the oran will he huilt. It is hest to complete all the pipes,
il possihle, helore commencin on any other portion ol the instru-
ment, as it ives them time to season and settle down, and should
there he any delects in the joints they will have time to demonstrate
their existence. It is very annoyin to nnd out these delects alter you
Ii. .Open
Diapason
Complete.
ORGAN BUILDING IOR AMATEURS. aq
have ot the oran into workin order, and thus have to leave other
work to remedy the mischiel. As reards paintin the
pipes, some persons advocate plain wood, lor the
excellent reason that the paint is olten used to hide
had materials and worse workmanship. This, how-
ever, is no reason why paint should not he used on
material and workmanship known to he ood, and my
own experience justines me in sayin that it improves
the tone in many cases, and undouhtedly preserves
the material, whilst it looks hetter than plain wood
lor pipes that are in siht.
In the concludin chapter will he lound a lew spe-
cincations lor orans ol a larer size, so that amateurs
who have plenty ol time and money at their disposal,
may ratily their wish to possess the hest instrument
within their reach.
In the meantime I would ure the would-he or-
an-huilder, helore startin on the work, to consider
the size ol the apartment in which the instrument is
to he placed, so that the oran may he suited to the
surroundins. It must he rememhered that, thouh a
sinle pipe does not sound very loud, a lull chord on
one stop ives a considerahle increase in tone, and
when all the stops are out and the couplers in action,
the noise would he simply unhearahle unless reat
care were exercised to keep down the power ol the pipes when in
course ol construction. Ior this reason I advocate pipes ol small
scale, with the mouths not cut too hih, as they can he made to
speak up well and yet not he noisy.
Ii. .
Gemshorn.
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CHAPTER III
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N ivin instructions respectin metal pipe makin I may say
that I have enerally rather deprecated amateur attempts in this
hranch ol oran construction, lor two reasons, viz. (), hecause
it is undouhtedly a lact that hut very lew amateurs possess the
requisite skill , and (a), hecause in most cases metal pipes could he
houht at a less costwhen the outlay lor tools and apparatus is
taken into accountthan that which would he incurred hy an
amateur in makin them lor himsell. But, as it is quite true that
amateurs have helore now turned out very creditahle work in this
hranch, I will now endeavour to descrihe, in as clear and concise a
lorm as possihle, the modus operandi, lor the henent ol those who
may he amhitious ol tryin their hand at this rather dilncult work.
Il amateurs intend to cast their own pipe metal, it will he neces-
sary that they should have a proper hench, lor which purpose many
manulacturers use a lare slah ol York stone or slate, whilst others
have a wooden hench.
As this latter lorm will prohahly he that most within the reach
and requirements ol the amateur, I will descrihe it more particularly.
The top or tahle ol the hench is lormed hy placin pieces ol stout
woodyellow deal will doahout . inch apart, and then holtin
them tihtly up, hut keepin them apart hy pieces ol thin stull. Il
you, do not propose to cast metal lor pipes larer than tenor C open
diapason, the hench top will require to he ahout leet lon and 8 or
ac inches wide, and should he lormed ol deals $ inch thick and
ahout $ inches wide, placed AECAP@9A, . inch apart, and holted up in
the manner descrihed. The planks should run lenthways ol the
M
!
METAL IOR PIPES. a
hench. True up hoth top and under side ol this tahle, and square it
at each ede. The hench or tahle top is now to he covered with a
piece ol ood linen, hed-tick or moleskin cloth. This should he
stretched tihtly over the top, hrouht down all round, and then
securely tacked on the under side ol the hench. See that this work is
well done, and that the tickin or moleskin lays perlectly smooth and
without wrinkles, and he carelul that there are no chips hetween the
tahle and the tickin, or anythin that would cause the slihtest
deviation lrom a level surlace. The tahle-top should now present an
appearance similar to that ol an artist's canvas stretched ready to
paint upon. The hench is then placed upon a pair ol trestles, or
otherwise nrmly supported, so that it lies quite level.
The castin hox is a simple allair, hut it must he stronly put to-
ether. Ii. shows hoth the hench and the castin hox, and it will
he seen that the latter is a square hox with a slopin hack, and is
nearly as lon as the hench is wide. It should he made ol oak at least
a inches thick, and may he or 6 inches wide at the top, and ahout
inches hih. It has no hottom, and the lront is made to slide up and
down a little way. This may he manaed hy cuttin a tenon on each
end ol the lront, and carelully nttin it into a roove at each end ol
the hox. A strip ol inch oak is nxed to the ends, so that it is raised
ahout $ inch ahove the lront, and a couple ol nne threaded thumh-
screws, or screws with ny nuts, are then screwed throuh the slips
into the top ol the lront, so that hy turnin them the lront may he
raised or lowered, so as to reulate the width ol the openin marked
C in Ii. at the hottom, throuh which the metal will now when
castin. The hottom edes ol the hox must he planed perlectly true,
so that no metal can run out except at the proper openin. A re-
hated runner is nxed on each end ol the hox, so that the rehates just
nt over the edes ol the hench, and allow the hox to he pushed
lreely hackwards and lorwards alon the top ol the hench. Now
screw a slip ol hrass alon the lront end ol the hench, as shown at B,
hrin the castin hox close up to it, so that the hrass securely closes
the openin at the hottom, and with a hradawl hore a couple ol holes
throuh each runner into the hench side , ahout an inch will he
sulncient. Il a stout wire is inserted in each ol these holes, the hox