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.
