Maintenance log for Winter/Spring/Summer
August 22, 2013
1) Completed rewinding of the English Post Horn rank so it doesn't
chatter with the tremulants on.
2) Two new ranks are installed in the Solo chamber, a Smith/Gottfried Open
Diapason and a Smith/Gottfried Vox Humana .
3) Tremulant on the Oboe Horn is corrected by installing metal separators
between the Oboe Horn and Post Horn chests.
4) Stated wiring of the traps and percussions in the Solo chamber.
1) Frans Bosman repaired the broken miters on the 16' Violone pipes
CCC and CCC#, and the CC3 of the Violin that broke off at the toe. The two 16'
Violone pipes hadn't spoken in years.
2) Re-installed the top octave chest for the Solo Tibia and replaced the
pipes with Wurlitzer Tibia pipes.
3) Replaced the 2' octave of the Main Tibia with brand new Wicks pipes.
September 7, 2012
1) Mike Bryant completed required changes to the Uniflex ODF to accommodate
the changes and additions to the Solo chamber .
2) The new Quintadena and Oboe Horn ranks are quite useful, the Oboe Horn is a
3) Tremulant on the Oboe Horn is much less deep than the other ranks on the same
regulator. Maybe due to the leather only separators absorbing the energy of the
4) Many slow notes on the English Post horn, more primary valve work needs to be
September 5, 2012
1) Completed wiring of the new English Post Horn chest to the
2) Inserted driver chips into output boards for the new rank..
August 27, 2012
1) Tuned Oboe Horn rank. The two replacement Wurlitzer pipes don't
want to tune.
2) Finished general clean up of Solo chamber.
3) Dropped C side Post Horn Bottom board and replaced four primary
valves. No leaks, two primaries still not responding correctly.
4) Cleared dead notes from C# side Post Horn. Replaced many Kimball magnet
armatures with the thicker OSI replacements, which seem to work better on the
higher pressure rank.
August 23, 2012
1) Installed ground buss bars on new two rank chest and connected
2) Started general clean up of Solo chamber.
3) Dropped C# side Oboe Horn Bottom board and replaced lowest two primary
valves. No longer leaks.
August 21, 2012
1) Installed the OSI/Wurlitzer tremulant. Made no difference in the
performance of the tremulant. Checked the regulator valves and repaired some
large holes in the pallet leather.
August 20, 2012
1) Installed the Vox Humana and Kinura pipes, rough tuned the Vox
Humana and checked tuning on the Quintedena.
2) Shortened the Solo 1 tremulant wind line but it made no difference in the
performance. Acquired an OSI copy of a large size Wurlitzer tremulant, will
August 17, 2012
Quintedena pipes are now installed voiced, regulated and tuned by Franz B. Many
stopper caps were re-packed. Cut-up raised on most pipes.
2) Fixed two dead notes on the Gamba rank by adjusting the primary valves.
3) Fixed numerous hissing wind leaks. The chamber is noticeably quieter
4) The Solo 1 tremulant unit may have to be relocated, doesn't want to adjust
properly. Easy fix to shorten wind line.
August 13, 2012
1) Lou Paff completed bushing the rack board with felt for the
2) Eight Quintedena pipes sent out for repair. They had dents and small cracks on the
cap solder joints which kept them from speaking properly..
3) English Post Horn winding is complete and set to 17" w/p. Installed C
side bottom board.
4) Started clearing leaks, dead notes and ciphers from Post Horn chest. Will
take some work to get it all playing.
August 3, 2012
1) Wiring complete on the Oboe horn chest. All notes play. CC# and
DD# have primary valves not seating correctly, will require removing bottom
board to fix.
2) Marc Gerlach completed enlarging the rack board holes for the Quintadena. Some
pipes required leather donuts around the toe to prevent them from protruding too
far into the chest toe hole. Many stoppers need to be repacked.
3) Layed out winding for the Post winker. One Post Horn bottom board was
August 2, 2012
1) Started wiring and re-gasketing the bottom boards for the English
Post Horn chest. Some primary valves require adjustment also.
July 27, 2012
1) Installation progresses on the two rank Kimball wind chest for the
new Morton Oboe Horn and existing Gottfried English Post Horn. Both ranks are
2) The new Marr & Colton Quintadena rank is being installed in place of the
existing Post Horn rank. This requires enlarging some rack board holes and
bushing others with adhesive felt. It will be winded with the Solo wind group,
which includes the Saxophone, Gamba, Gamba Celeste, Kinura and Quintadena.
July 23, 2012
1) Removed old Kimball single rank wind chest and installed the new
two rank wind chest. The Marr & Colton Horn rank will be replaced by a
Morton Oboe Horn.
2) Modified wind line to the Oboe Horn chest. Pressure tested Oboe horn
3) Marc Gerlach started racking up the Marr & Colton Quintadena.
July 13, 2012
1) Finished making new rack boards for the modified two rank Kimball
2) New end pieces finished to convert the Kimball 3 rank chest into a two rank
chest. New two rank configuration is now completed.
June 25, 2012
1) Completed cleaning the Robert Morton Oboe Horn rank. All pipes
have been wet cleaned, stripped and new lacquer applied to the zinc portions.
Larger pipes were cleaned by spraying "Scrubbing
Bubbles" cleaner on them and pressure washing them. All reeds and shallots
have been cleaned and resurfaced. All were full of coal dust
April 13, 2012
1) Key contacts on all manuals adjusted for correct contact height,
including 2nd touch.
2) Changed progression of Solo swell shades sequence, so the volume change is
smoother. Exchanged bottom shades for top shades.
March 26, 2012
1) Lowered pressure on the English Post Horn from 18 1/2" to
17". Not much difference in pitch. Rank is more manageable now.
2) Chris Nordwall tuned all ranks in the Solo chamber.
March 25, 2012
1) Lubricated the front and back bearings on the blower motor.
2) repaired dead notes in Main Tibia and Diapason
3) Chris Nordwall tuned all ranks in the main chamber. Tonal finish was done to
the Tuba Horn and Diapason in the Main.
August 15, 2011
1) Fixed two dead notes in Main Tibia wind chest Low A# had particle
lodged in the primary valve. Low C# required primary valve adjustment.
2) Re-gasketed the bottom board on Main Tibia Clausa C side, and cleaned
the primary valve sealing surface.
July 08, 2011
1) Set pressure for the new Morton Solo Vox Humana. Was not able to
get 6" pressure due to incorrect springs. Will acquire low tension springs.
Set pressure to 8".
2) Tuned Solo Vox Humana and set tremulant speed. Sounds pretty good.
3) Touched up tuning on Kinura, Main Tibia and Diapason
July 05, 2011
1) Rank board holes for the Morton Solo Vox Humana was
re-drilled to accommodate the larger scale.
2) Installed Solo Vox rack board and Robert Morton pipes. Fits well into chest.
Many pipes are much taller. The new rank is from the Morton organ originally
installed in the Sequoia theater in Burlingame, California. Rank was originally
voiced on 6" wind pressure.
3) Prepared 6 more of the Main Tibia Clausa pipes for installation, stoppers
repacked and new leather on the lips.
March 22, 2011
1) Organ was tuned by Chris Nordwall for upcoming recording session
2) Completed reconfiguring "D" files on the Uniflex system for the
Main Diapason and included the 4' octave pipes in the rank, which were never
3) Regulation of the new main Diapason rank completed. Very nice.
4) Installed 11 rebuilt pneumatic motors on Chrysoglott action. Its sounds
pretty good now.
5) Final adjustment of the Solo Tibia tremulant completed
6) Installed some additional sound adsorption panels in both chambers, making
the overall sound a little tighter.
March 4, 2011
1) Made some adjustments to the rebuilt Wurlitzer Solo Tibia tremulant unit.
Required opening the gate valve to keep it from stalling. Between this repair
and previous repairs, the noise level of the instrument has been dramatically
2) Reconfigured "D" files on the Uniflex system for the Main Diapason
and included the 4' octave pipes in the rank, which were never present before.
3) Did some rough tuning and regulation of the new main Diapason rank. It is
just what was needed. It is much louder and present than the original Wicks
rank. It sill requires the rest of the tuning collars installed, and final
February 18, 2011
1) Completed installation of rebuilt Wurlitzer Solo Tibia tremulant unit. New
pallet valve and gasketing was done along with some cosmetic
improvements. No more squeaks when turning off and on. It runs well and is
quiet. The tremulant wind line is about 18" shorter then before.
February 11, 2011
1) Started rebuild on the Solo Wurlitzer Tibia tremulant unit. New
pallet valve and gasketing is required along with some cosmetic
2) The new Main Diapason rank has new tuning collars attached so it can be tuned more easily.
February 2 & 4, 2011
1) Installed new Wurlitzer Tibia tremulant unit. This runs much
better that the OSI unit it replaces and is very noticeably much quieter than as
well. This one change reduces the overall mechanical noise of the instrument
2) Started the replacement of the Wicks Diapason rank when the new one. The new
rank is larger scale and will provide a better foundation sound for the organ.
It will need tuning collars attached so it can be tuned more easily.
3) Started the replacement of the main Tibia rank wood pipes with a larger scale
Dennison rank. Some pipes will require repacking the stoppers.
January 20, 2011
1) Rebuilt a Wurlitzer tremulant unit to replace the noisy Main Tibia tremulant.
Pictures below depict the unit in pieces before assembly. All pneumatic motors
were recovered with new rubber cloth, new gate valve constructed to accommodate
the 2 1/2" PVC pipe, and most all pieces were striped and shellacked.
Maintenance log for Fall/Winter 2009
& year 2010
December 8, 2010
1) The entire organ was tuned by Chris Nordwall of Rose City organ
July 21, 2010
1) Bob Macneur installed and wired Reisner/OSI magnets in 8' Main trumpet offset
chest, replacing the external wired originals. Chest needs winding and
2) Mike Bryant reconfigured both the Main and Solo swell shades configuration.
All swell shades in the Solo now open, and only the Main shades that have no
linkages are dead. The original configuration in the definition file was totally
incorrect and did not have the swell shoe potentiometers range accounted for
correctly. This really opened up the sound of the organ.
July 12, 2010
1) Installed partially rebuilt pouch board in the C# side of the Oboe Horn
windchest. The pouch board required this as there were four partial ciphers. No
ciphers now. Also repaired wind leaks on the top board seal. The chest is now
almost leak free.
2) Finalized the wind line connection to the Oboe Horn chest. Resized one
segment so its is straight and secured fittings with sheet metal
3) Installed wind line supports for Oboe Horn and static wind to the
4) Completed felt bushing for Oboe Horn rack board holes.
5) Applied felt strip to top of Solo Tibia tremulant unit so that it seals
better. The unit needs to be removed to repair wind leaks and fix squeak when
tremulant is shut off and on.
June 29, 2010
1) Chris Nordwall, with the assistance of Tom Sylar, tuned the entire organ,
including most pedal offsets. The organ sounds fantastic.
2) Wired Bass Drum and cymbal action to spreader. Repaired leaking primary valve
on tap cymbal and other wind leaks on traps counter. Replaced strap on Persian
Cymbal so that the Roll Cymbal works better.
3) Wind pressure on Chrysoglott and Traps now 15" with the addition of
another leaf spring. The Chrysoglott and traps sound much better, snappier.
June 28, 2010
1) Dennis Hedberg did total work on the Oboe Horn, Saxophone, Main Tuba Horn and
low 6 notes of the Moller French Trumpet. The Oboe Horn is now very useful as an
accompaniment stop. The Main Tuba Horn
is very even, nicely regulated.
2) Bob MacNeur winded the Kimball Bass drum and Cymbal action. Needs balance of
wiring and adjustment..
3) Found wind pressure on Chrysoglott and Traps now too low (11 1/2").
Needs another leaf spring added to winker.
June 25, 2010
1) Installed low 12 resonators of Solo Oboe Horn rank, ready for tuning.
2) The Chrysoglott is getting a minor rebuild by Bob MacNeur. The hammers will
be re-felted and blown pneumatic motors repaired.
3) Fixed non-functional stops on Accomp, Solo and Great divisions. Accomp 4'
Gambas, Great 16' Trumpet, Solo 8' English Post Horn.
4) The Kimball Bass drum and Cymbal action has been installed. Needs balance of
wiring and winding.
5) Fixed dead middle E in Main Diapason, incorrect assignment in ODF.
6) Jonas changed transpose buttons on console to combination level
up/down and load
7) Mike fixed key contact on middle D# on the Great manual. Required burnishing
June 21, 2010
1) Installed 12 note offset chest for main 8' French Trumpet rank. Wiring and
winding still to be done.
2) Main Tuba/diapason regulator has been replaced and is working fine. Set
pressure 10 1/2" pressure.
3) Solo Oboe Horn rank has been installed and tuned down to tenor C. The wind
chest will require more work to removed ciphers and leaks.
4) The Chrysoglott is getting a minor rebuild by Bob MacNeur. The hammers will
be re-felted and blown pneumatic motors repaired.
5) Mike Bryant is working over the console, adjusting contact firing points on
the manuals and tightening loose stop tabs on the name board.
6) The Kimball Bass drum and Cymbal action has been rebuilt and is ready to
May 11, 2010
1) Got the metal Glockenspiel hammers from the beadblaster and laquered them.
Ready to install.
2) Removed the leaking Main Tuba/diapason regulator for recovering.
Unfortunately, it was sealed to the wind trunk with Silicone gel. The Silicone
gel did not separate properly and destroyed the the bottom of the regulator and
damaged the top of the wind trunk. Will require a new bottom made and a repair
to the top of the wind trunk.
May 5, 2010
1) All dead notes in the Main Trumpet rank repaired. Rank has been tuned.
2) Replaced C# side pouch board from the Main Vox Humana chest after partial
3) Installed repaired Tuba Horn resonators and tuned the pipes.
4) Finished the repair on the main Tuba Horn/Diapason tremulant unit.
Re-positioned weights on the Tuba regulator so the excursion is even when
tremulant is running. The regulator is badly in need of re-leathering. The
gussets are leaking. Temporarily fixed with Gorilla tape
5) Bob Macneur installed a loaner Wurlitzer Cymbal action in the Main
chamber. It is beautifully restored.
May 4, 2010
1) Repaired three dead notes in the Main Trumpet rank. Required dropping bottom
boards and pouch boards. Low C had defective magnet. Low D was ciphering because
of PVC particles in the primary. Low G was dead due to a blown pouch
2) Removed C# side pouch board from the Main Vox Humana chest for partial
3) Replaced defective magnet in English Horn low D#. Required dropping bottom
board to replace.
4) Picked up repaired Tuba Horn pipes from Mike deSarte.
May 3, 2010
1) Dennis Hedberg finished voicing the Gottfreid English Horn, and did
some work on the Saxophone. He removed brass sleeves and other restrictors that
were muffling the upper end. Much better.
2) Tuned all the major reeds plus the Saxophone, Kinura and Orchestral
3) Mike Bryant and Bob MacNeu repaired dead notes in the Main chamber.
April 30, 2010
1) Installed more acoustical panels in the Main and Solo chambers. There is a
dramatic change in the overall sound because the excess ambience in the chambers
is damped out. The Solo Tibia tremulant is more more defined, and the overall
responsiveness of the attack of all ranks is much more defined.
2) Completed modification of the console pedal board attachment hardware. No
more lifting and cursing when connecting the pedal board. Just slide it into
position. The pedal board frame is on adjustable leveling pads so the height can
be adjusted very accurately. No more adjusting the magnetic reed switch
April 28, 2010
1) Started wind and wiring the Oboe Horn wind chest. About halfway thru each
2) Moved some large sized acoustical panels into the Solo chamber to damp excess
ambience in the chamber.
April 21, 2010
1) Completed sizing the rack board holes for the Oboe Horn chest.
April 19, 2010
1) Completed re-leathering of the Solo C side Diapason pouch board, using
OSI manufactured pouches.
April 16, 2010
1) Placed the Oboe Horn wind chest on its chest bearers. Ready to install bottom
boards and wind lines
April 15, 2010
1) Started to assemble the chest bearers for the new Kimball Oboe Horn windchest.
April 2, 2010
1) Dennis Hedberg did some more tonal finishing on the Gottfried English Horn.
Several dead notes on the low octave need to be corrected. The low C# pipe
2) The Devtronix computer locked up twice during the open console event
March 26, 2010
1) Removed pouch board from Solo C side Diapason chest to send to OSI for
2) Acquired large sound treatment panels to install in both chambers to dampen
3) Repaired two broken solder joints on resonators for the French Trumpet and
the low f# on the English Horn
March 24, 2010
1) Dennis Hedburg started tonal work on Gottfried English (post) Horn
rank. The wind pressure was raised to 18 1/2" W/C (water
column). The work is nearly complete and will take another session to
complete. But the difference is astonishing, its a completely new rank. One
small pipe is missing the reed tongue and shallot. The low C# pipe is missing
and apparently has been gone since the rank was installed in Benson high school.
The organ now has four very good chorus reed stops. (English Horn, Trumpet,
Harmonic Tuba, Tuba Horn)
2) Chased more dead notes in the main chamber. Some will require dropping bottom
boards to fix.
3) Started to process of acquiring replacement chest pouch pneumatics from Organ
Supply, inc (OSI).
March 23, 2010
1) Made back-up copy of the files in the Devtronix computer for
2) Dennis Hedburg started tonal work on some reed ranks, including the Main Tuba
Horn and Trumpet and the Solo Harmonic Tuba and Saxophone.
The Saxophone is much better being more even and the
Solo Harmonic Tuba is very nice. The tonal work is called regulation and
consists of making the pipes equal in volume, timbre and the way they take
the tremulant consistent within the rank. The tenor
"G" in the tuba was too buzzy. When Dennis took it apart, he found a
dead insect carcass in the shallot. The note sounds much better without the
March 18, 2010
1) Finished bushing loose rack board holes on the new Trumpet
rank with adhesive backed felt from Grainger
2) Completed bushing loose Main Tibia racking with felt. They look much
straighter and will be more stable and easier to tune.
3) Started to rework the hammers on the Chrysoglott with softer felt. It will
sound much more delicate and Celesta like when completed.
4) The new chest bearers for the Oboe horn chest are complete. They were
finished shellacked by Bob Macneur.
5) Ordered and received the M66 blocks required to wire up the Oboe Horn chest.
Also have the insertion tool for the M66 blocks.
February 22, 2010
1) Work continues on the single rank Kimball chest for
the Oboe Horn. New rack board for C# side made, along with support pins, pipe
stays (reworked from Main Trumpet chest) and "hi-hats".
2) Started work on releathering the Bass Drum/Cymbal action. Pneumatics are full
of coal dust, very messy.
February 11, 2010
1) Installed most of the Wurlitzer Tuba Horn rank,
with the rebuilt pipe stays. Pressure is set to about 12" w/c. Rank boards
holes were enlarged using a router and purpose built templates. A few pipes are
still out for repair.
2) Replaced the not so good Morton Trumpet rank with an M. P. Moeller French
Trumpet. It really has the OK sound, being very much like a Wurlitzer
"brass" Trumpet. It is only from Tenor "c" for now until the
offset chest for the lowest 12 pipes is installed. It is the rank with the
flared bells, between the Flute Celeste and the Wurlitzer Orchestral Oboe.
February 6, 2010
1) Began work on the single rank wind chest that will
be for the Dennison Oboe rank in the Solo chamber. Rejoined to two halves into
one chest. The chest was rebuilt previously and will not require new leather.
November 25, 2009
1) Transferred cleaned Harmonic Tuba pipes to CHS main
chamber. It will require reaming the rack board holes to allow them to fit.
2) Installed new Wurlitzer winker for the Solo Glockenspiel and Xylophone,
removing these items from the pedal offset winding. They are now on their own
separate wind supply, set at 16" wind pressure
November 19, 2009
1) Cleared all dead notes from the Main Diapason rank
2) Installed new walk board between the back two windchests
3) Started looking into replacement of the too soft Main Wicks Diapason rank.
Have located a suitable replacement.
4) Damaged Tuba Horn and Orchestral Oboe pipes were sent off to Mike DeSarte for
Overview of Solo/Main Chamber Retrofit - Summer of 2009
of the chief complaints about the Cleveland High School organ has been the
"soft" and non-distinct sound of the Solo chamber. In this case,
"soft" does not pertain to the loudness of the chamber, it can get
plenty loud. The term "soft" refers to the lack of definition of the
ranks, and particularly the Tibia tremulant. This is caused by the size of the
chamber, which is almost double the volume required for the amount of ranks and
other effects installed in it.
The obvious solution would be to lower the ceiling
about 6-8 feet, but the logistics and cost of this would be prohibitive. This,
in conjunction with raising the windchests
would be the best solution. The best alternate option was to raise the
windchests at least 18". The rear, 3 rank chest was raised a total of 22
3/4" and the forward 4 rank, Kinura and Vox Humana chests were raised a
total of 18 3/4". This dramatically increased the ease of maintenance of
all the wind chests.
Four other things were done during the Solo chamber retrofit.
First, the sound killing walk board that ran over the center of the chests was
eliminated. It was extremely precarious to tune and work on pipes from it, plus
it blocked the sound of the treble pipes. Second, the Kinura chest was lowered so
that it didn't block the egress of the solo chamber pipes. Third,
the old walkboard was cut down to 16" wide and installed between the two
larger chests, so tuning and voicing pipes will be a lot easier. Finally,
12" square acoustical tiles and other types of acoustical treatment were attached to the walls of the chamber. The
tiles' purpose is to dampen excessive reverberation in the chamber. Although
this sounds counterintuitive, this is meant to increase the clarity of the sound
emanating from the chamber and to help define the Tibia tremulant.
Some changes in the winding scheme of the ranks was
done during the course of reconnecting windlines. The Tibia Clausa was
originally winded from the back of the chest with a 5" wind line. Since
5" PVC is not readily available, the wind line was changed to 4", and
was winded from the side of the chest. The interesting "Y"
configuration on the Solo tremulant was deleted. The OSI tremulant unit on
the Tibia Clausa was replaced by a Wurlitzer large scale tremulant, graciously
donated by a member.
Main Chamber Project
Main chamber suffers from the same installation errors as the Solo Chamber, but
there is more hardware packed into the same size chamber. The rear wind chest
that has the Main Tibia Clausa, Open Diapason and Harmonic Tuba was raised
24" and moved back 16". It required full reconfiguring of the
winding system, with new 4" PVC wind lines and relocating the tremulants.
The single rank Morton windchest that had the 4' Octave was deleted to make
The sound killing walkboards that ran through the
center of the wind chests were also removed and a 15" wide walk board was
installed between the back two wind chests. This allows easy maintenance and
tuning of the Harmonic Tuba, Orchestral Oboe, and Trumpet ranks.
Almost all of the original windlines on the other two
main chests was also removed, including 40 pounds of 5" PVC line. The new
winding schemes are much simpler and less of a trip hazard. It is totally
amazing how much better things work when simplified. We keep on removing things
and the organ works and sounds better!
After measuring the wind pressure on the ranks
fed by Main I regulator, it was discovered that the pressure was too low
(< 10"). The pressure was raised to about 12" by adding two large
springs to the regulator, for a total of six springs. The sound of the Kimball
Violins and Concert Flute was dramatically improved. All the other wind
pressures were checked and adjusted as required.
The Main Vox Humana, a Wurlitzer rank, was louder than
the new Morton Solo Vox Humana. The rank was re-regulated by closing the tops
down so it is somewhat softer, blending better with the strings and
The blower has been a
potential Achilles Heal on this organ for years. The blower itself has been
installed in three or four different venues in its lifetime and soon will be on
its third motor (the current DC motor was not the original motor) . Since
July 24, 2009, the blower has not been functional because of a partially shorted
oil damped starter coil. The blower could be started but the coil would start to
smoke after about a minutes operation.
DC motor and blower issues:
1) The DC motor was rated at 1150 RPM at 230 VDC. It was running on at least 270
VDC and probably running faster than the 1150 RPM. Because of that, one of
the fans was removed to have to blower output less pressure, which has been
reported as 30" + static pressure. The higher RPM contributed to more
turbulence and wind noise. We were quoted $400-600 to install new motor brushes
and service the bearings.
2) The Cutler-Hammer DC motor starter dates from 1914, was obsoleted in 1933,
and the last spare parts were made in the 1960's. It has been modified over
time, the contacts are burned and is otherwise unreliable and unsafe. DC was
used when organ blowers were run off of city streetcar power. We were quoted
$600.00 to rewind the starter motor coil. There is no real way to tell what
other real or potential problems exist in the starter apparatus.
3) The fan that was removed had been installed at one time but was incorrectly
installed so that it scraped against the adjacent stator. There were numerous
aluminum particles found in the outlet butterfly valve. The rivets on the fan
were worn down and the edges were sufficiently scraped so the fan has to be
replaced, at an additional cost of $400.00.
The cost of repairing the DC motor and starter
would be almost half of the cost of as new motor. And there still might have
been hidden problems with the starter and motor. So, to ensure continued
reliability, the decision was made to replace the DC motor with new 3 phase, 208
VAC, 20 HP motor. It will have three fans and will deliver sufficient
static pressure to ensure no sagging wind pressure.
On October 6th, 2009, the new motor was
installed by Bob Otey of Seattle. The blower now has the original 3 stage
configuration and produces 23 1/2" static pressure at the blower. The
blower was balanced electronically and runs extremely smooth. The old blower
configuration imparted a low level rumble that could be heard throughout the
entire building. That noise is now completely gone and the organ makes no noise
when the swell shades are closed.
Maintenance log for Summer 2009
Below is a log of the daily events (starting
from the latest date):
Day 47 October 9, 2009
1) Moved console into auditorium for publicity photo
2) The entire organ is noticeably quieter in the auditorium. With the swell
shades closed, there is no noise heard from the organ. Before the blower motor
replacement and balancing, there was a noticeable low frequency rumble heard in
3) Installed rack boards for the Main Diapason and Tibia Clausa and planted the
4) With the direction of Dennis Hedberg, numerous adjustments were made in the
regulators and wind pressures.
5) Fixed leaks and ciphers on the Solo toy counter assembly.
6) There are still some minor leaks on the Main Tibia chest toe boards which
can't be fixed unless the chest is re-gasketed.
Day 46 October 8, 2009
1) The Tibia portion of the Main 3 rank chest continued to leak even after
shimming the screw holes with match sticks. It was decided to drill out the
holes and insert dowels.
2) Secured the bottom boards and the other two toe boards on the 3 rank chest.
3) Fixed numerous small wind leaks.
Day 45 October 7, 2009
1) Checked operation of blower in the chambers, some new
leaks to be addressed.
2) Started reassembly of the Main 3 rank chest after blowing out accumulated
dirt and dust. Even with vacuuming out the chests, there was still a lot of dirt
and dust inside.
Day 44 October 6, 2009
1) Installed new 20 Hp blower motor. All three stages
were electronically balanced and the blower runs very smoothly. Measured static
pressure at the blower is 23 1/2"
2) No apparent problems with the electrical service to the blower, no failures
after repeated starts and stops.
Day 43 September 24, 2009
1) Removed old DC motor from blower so new motor can
be installed next week. Required an engine hoist, floor jack and a pallet jack
borrowed from the high school.
2) Confirmed that existing motor starter is adequate for the new blower
Day 42 (August 31, 2009)
1) Completed the connection of the 4" windline
for the Main center windchest.
2) Installed metal cleats for the toy counter.
Day 41 (August 28, 2009)
1) Gary Hughes connected all the traps wiring in the Main chamber
and all the tremulant control wires.
2) Placed the rest of the Solo Violin Diapason, some pipes will need bushing on
the toes. Also, rolled out some dents in selected pipes.
3) Max did an extensive clean-up in the Solo chamber.
Day 40 (August 27, 2009)
1) Moved surplus pipes to storage
2) Milled some required parts for the Main 2 regulator windline connection and
Solo Xylophone/Glockenspiel winker
3) Planted the most of the new Gottfried (?) Violin Diapason in the Solo
chamber. Because the scale of the original Kimball Diaphonic Diapason was so
big, the new pipes were re-scaled in the manual chest, so the lowest pipe on the
manual chest is 8' GG. There 7 notes offset (CC thru FF#). Originally, the
Kimball Diapason started at tenor C on the manual chest and the lowest 12 notes
4) Received the 1 rank Kimball for the Oboe Horn in the Solo chamber, stored in
blower room for now
Day 39 (August 26, 2009)
1) Cut and installed new 4" windline for the Main 2
2) Installed 3" windline for the Solo chamber toy counter.
3) located the main breaker panel that feeds the breaker panel in the Main
chamber. It is located in the ante room in the Chemistry lab next door to the
main chamber. (panel C-1, 70 amp breaker, panel is rated at 225 amps.)
4) Prepared the Wurlitzer winker for installation on the Solo
Day 38 (August 25, 2009)
1) Max completed the installation of the Main 2' Tibia offset
chest by securing the cables and running a ground wire. Soldered the wires as
they were never soldered.
2) Started the winding of the Main 2 regulator to the middle 3 rank chest
3) Ran windline for the Main toy counter and secured signal cable
to the terminal board.
Day 37 (August 14, 2009)
1) Completed the new Vox Humana and Main I tremulant windlines
2) Marc Gerlack did a great job of preparing the side of the center Main cheat
for the refurbished side plate
3) Jerry Hertel prepared and glued new gaskets for the old side
4) Max installed side plate and installed new wind lines
5) Mike Bryant prepared the 2' Tibia 12 note chest for installation
6) Installed above Tibia chest
Day 36 (August 13, 2009)
1) Completed Tuba/Diapason tremulant line, which required
modifying a support on the 16' Open Wood offset chest.
2) Secured the Main Tibia tremulant to the floor
3) Started to clean up the old Main and Vox Humana tremulant lines so they
aren't trip hazards and they are more straight forward in configuration. Not so
4) Discovered the most egregious, most amateurish and downright damaging
silicone gel job yet in the center three rank chest. This won't be corrected in
this round of retrofits.
5) Jonas donated a fully rebuilt Wurlitzer equalizer (winker). It will be used
to improve the winding of the Solo Xylophone and Glockenspiel.
Day 35 (August 12, 2009)
1) Completed all ground wire and buss connections to 3 rank chest
2) Moved 3" Bourdon windline to make way for the Tuba Tremulant line
3) Made an adjustment to the 4" Tuba windline and finished
4) Mike Bryant completed repair to the Tuba toe board and placed it on the wind
5) Ordered PVC pipe and fittings for Tuba tremulant windline
6) Started general clean up of the Main chamber
Day 34 (August 11, 2009)
1) Completed windlines for Main Tibia Clausa feed and tremulant
2) installed 4" adaptor and flange on Tuba/Diapason regulator.
3) Jonas and Marc completed the cutting and fitting the windline for the Main
4) Finally found the circuit breaker for the blower motor. It was in the Main
chamber, not where we expected it to be.
Day 33 (August 10, 2009)
1) Started cutting wind lines for the Main Tibia Clausa and Tuba
2) Jonas completed installation of the Solo Vox Humana
3) Check sent for initial payment for new AC blower motor.
4) secured and dressed wiring for the Main 3 rank chest
5) Installed bottom boards with two screws each to get them out of the way and
out of danger.
Day 32 (August 06, 2009)
1) No access to3rd floor due to floor waxing
2) Took measurements for Bob Otey to construct brackets for new blower
3) Blower fans have been delivered to Bob Otey.
Day 31 (August 06, 2009)
1) No activity in the chambers due to floor cleaning and waxing
on the 3rd floor
2) Dismantled blower for preparation for the new 20 HP, 208 VAC, 3 phase motor
to be supplied by Bob Otey of Seattle. Found metal shavings on top of the outlet
butterfly valve due to incorrect installation of the
outer fan, which was scraping on the stator. Max noticed a
cracked weld on the bracket that held one of the motor brushes. Overall, the
decision to replace the DC motor with a new AC motor is a good
one, looking at all the inherent problems with the
Day 30 (August 05, 2009)
1) Max installed ground busses and wires for 3 rank chest
2) Installed new side panel for 3 rank chest
3) Mike finished the new gaskets for the Tuba toe board pouch rails.
4) Started preparation for the 4" windline connection on the Tuba regulator
Day 29 (August 04, 2009)
1) Secured another wiring terminal strip and began cleaning up
2) Mike completed the new gaskets on the Tibia toe board pouch rail, placed toe
board on chest.
3) Hauled off excess pipework and wind chest to storage.
4) Acquired a Robert Morton 10" scale Vox Humana for the Solo Chamber.
Jonas and Marc Gerlach installed it.
5) Mike and Max started preparing the Tuba toe board for new gaskets on the
6) Jonas and Marc started to disassemble the blower for conversion to a new AC
Day 28 (August 03, 2009)
1) Assembled new chest bearers for 3 rank chest in hallway
2) Moved and reassembled chest frame and bearers in the Main chamber
3) Secured new chest bearers to the floor with 1" plywood pads using
1/4" lag bolts
4) installed one Tibia bottom board and secured cable terminal strip
5) Mike inspected the toe boards for the Tibia and Diapason, will require new
paper gaskets on the Tibia pouch rails. Pouch leather looks OK.
6) Jonas inquired about additional options for the blower. It may cost thousands
Day 27 (July 31, 2009)
1) Removed and prepared the Main back 3 rank windchest frame for
installation. It required lots of filling putty, sanding and bushing screw holes
and other repairs.
2) Cleaned out and removed almost all of the hardware in the hallway.
Access to the organ chambers will be limited next week when the CHS
custodians wax the floor.
3) Gary Hughes brought in a capacitive/inductive tester and determined that the
blower starting coil is partially shorted. We will find a licensed shop that can
rewind the coil.
4) Received some documentation on the blower motor
starter unit from Cutler-Hammer, which was obsoleted in 1933.
Day 26 (July 30, 2009)
Work was canceled yesterday due to the extremely hot
1) Ran ground wire for the 12 note Tibia 2' chest
2) Connected the Solo and Solo Brass tremulant control wires
3) Cleaned the Solo chamber and removed all the accumulated tools and supplies
4) Started to clean the hallway of all accumulated parts and lumber
4) Had an electrician look at the blower motor starter device to explore options
to repair or upgrade
Day 25 (July 27, 2009)
1) Still looking at options for the blower starter
2) Fixed a crack in a Solo Tibia bottom board
3) Started winding the traps in the Main chamber
4) Continued with the dismantling of the Main rear 3 rank chest. Found more
Silicone gel troubles but found an adaptor on a 12 note treble chest that
actually had a leather gasket on it!
Day 24 (July 24, 2009)
1) Fixed some leaks on the Solo manifold
2) Fixed a cipher in the Solo Tibia, which required dropping the bottom board,
yet another glob of silicone gel. See picture below.
3) Fixed a dead note in the Solo Tibia which required removing the Tibia pipes
and the toe board. The dead note was caused by a port not opened when the new
gasket material was glued in. The new gasket material was required because of
the silicone gel used to fix leaks. See #item 2 and entry from day 2.
4) The DC starter device on the blower motor failed. The organ is non functional
until this is fixed. Various options are being explored. It is not known how
long this will take or how much it will cost.
Day 23 (July 23, 2009)
1) Max finished installing the new screws into the Kinura
chest bottom board. No leaks! Replaced the old 3" #12 straight slot flat
head screws with Philips head screws, along with new washers..
2) Planted the Kinura pipes
3) Jonas experimented more with the Solo Tibia tremulant, shortened the windline
4) Did some re-winding in the Main chamber to allow the blower to be turned on
again. The new winding when installed will be much simpler and
5) Removed the center walkboard from the Main chamber
6) Had a large crew today, so we were able to hoist the Main traps assembly into
place on top of the Harp. It fits like its supposed to. Its ready to wind and
Day 22 (July 22, 2009)
1) Finished winding the Kinura chest
2) Fixed wind leak on Solo manifold
3) Checked and set wind pressures in Solo chamber. Set as follows:
a) Solo - 10 1/2"
b) Solo Brass - 11"
c) Tibia Clausa - 13 1/2"
d) Vox Humana - 6"
4) Secured terminal board for the Solo 4 rank chest
5) Started work on raising at least one of the Main windchests by removing the
Main Tibia and Diapason ranks and removing the toe boards on the 3 rank
Day 21 (July 21, 2009)
1) Wheeled out the console and heard the results of the
work. The sound is much improved, even though everything is very out of tune.
2) Cleared a cipher from the Solo Tuba that required dropping a bottom board.
Yet another glob of silicone gel lodged in the primary valve.
3) Discovered a dead note in the Solo Tibia (middle A) probably a blown pouch.
4) The Morton Diapason transplanted form the main chamber is still too tubby for
the desired sound.
Day 20 (July 20, 2009)
- one small step for a man.................
1) Fastened the 2' Tibia rack board and planted the pipes
2) Installed Kinura chest with new chest bearers. Routed the Solo tremulant line
through the chest bearer to save space.
3) Completed tying the pipe stays for the English Horn
4) Confirmed measurements for the Main chamber move
5) A subjective measurement of the Solo vs. the Main reverb times indicates the
Solo is now tighter than the main.
Day 19 (July 17, 2009)
1) Finished installing Diapason pipes including 4' Octave
2) Planted the 4' Clarion pipes
3) Max cut and glued the gaskets for the 2' Tibia extension wind chest
4) Mounted the 2' Tibia extension wind chest, Max secured the wiring for
5) Fixed cipher in Diapason chest, required dropping the bottom board
6) Planted the Tibia Clausa pipes on the wind chest, with the help of Bob
7) Mounted the acoustical tile donated by Jerry Hertel. The room is definitely
getting tighter, less reverberant.
Day 18 (July 16, 2009)
1) Installed the rest of the English Horn, Diapason
and Harmonic Tuba ranks using brand new cotton twill tape on the pipe stays.
Discovered that the Harmonic Tuba is harmonic from Tenor C on up.
2) Installed the Trivo Saxophone
3) Jonas has made some preliminary adjustments on the tremulants
Day 17 (July 15, 2009)
1) Installed Gamba, Gamba Celeste ranks.
2) Started to install English Horn, Diapason and Harmonic Tuba ranks. Discovered
that the tenor D and D# boots on the Harmonic Tuba had been swapped when last
3) Repaired one blown pneumatic pouch on the C side of the Diapason, another one
was to far gone top repair.
4) Fixed ciphers on the Tuba chest, found screws holes drilled horizontally into
the to boards were leaking. Plugged holes. Probably the same solution on the
Post horn chest.
5) Made new rear plate for the 12 note Tibia 2' extension chest
Day 16 (July 14, 2009)
1) Installed braces for Tibia Clausa tremulant.
2) Installed new 5" PVC wind line extension for the Solo ranks
3) Chased more wind leaks and ciphers on the Solo windchest. Required dropping
one bottom board.
4) Drilled 1 1/2" hole for the 2' Tibia 12 note extension windchest. Cannot
install the chest as the back plate has to be reworked. Plugged hole.
Day 15 (July 13, 2009)
1) Repaired pneumatic motor on the large Wurlitzer tremulant
unit and assembled the tremulant.
2) Installed new Tibia Clausa tremulant wind line. It really
shakes that regualtor! It will have to have a gate valve to scale back the
tremulant a bit.
3) Chased more wind leaks and ciphers
4) Installed braces for Solo Brass tremulant wind line
Day 14 (July 10, 2009)
1) Installed new ladder for accessing the walkboard in
front of the Tibia Clausa offset
2) Secured Solo tremulant to the floor and 4" wind line going to the Piano
3) Spent the rest of the day chasing ciphers and dead notes.
4) Ordered more 2 1/2" pipe for the Tibia Tremulant wind line
Day 13 (July 9, 2009)
1) Installed new wind line for the Solo Brass
tremulant. (see picture below)
2) Installed new wind line for the Solo tremulant
3) Paul Quarino donated a large size Wurlitzer Tremulant for the Solo Tibia
Clausa. It will require a very minor rebuild before installing, Many thanks to
4) Mike Bryant and Rob Kingdom decide to relocate the Kinura windchest so that
it will be directly in front of the Vox Humana wind chest. This will be the
closest rank to the swell shades for maximum egress.
5) Jack Powers finished the ground wires for all the chests.
Day 12 (July 8, 2009)
1) Installed 2 1/2" Vox Humana tremulant wind
2) Started fixing leaks and ciphers. Lots of debris in the chests including a
small clump of Silicone gel lodged in a primary valve. This required dropping 3
bottom boards to address these issues.
3) The primary pneumatics we saw were in very good condition, they should be
reliable for years to come.
Day 11 (July 7, 2009)
1) Max installed the corner brackets on Vox Humana chest, trimmed the walk board
support so the new Tibia wind line would clear
2) Connected the separate 4" wind supply wind lines to the Tibia Clausa and
3) Secured the wiring terminal for the Vox Humana chest.
4) Connected the new wind lines for the English (post) Horn.
5) Max and Steve Jarvis installed the Vox Humana bottom board and ensured that
all the screws secured correctly.
6) The one "Wurlitzer" tremulant unit we have turns out to be
Robert Morton. Probably will install it where it was before but with cleaned up
wind lines. Anybody out there that would like to donate a large Wurlitzer
7) Turned on the blower a couple of different times to blow out the chests.
Quite a few ciphers left over from before the move. Plugged a few leaking screw
holes. No apparent leaks in the new winding.
Day 10 (July 6, 2009)
1) Max installed all the required flanges for the
various wind lines (not "air pipes")
2) Connected the wind supply to the Vox Humana wind chest and placed the chest.
3) Secured the wiring terminal for the 4 rank chest.
4) Jack finished replacing the missing magnet on the Vox Humana chest and
checked all the remaining magnets.
5) Jonas Nordwall inspected the work and was duly impressed. He suggested that
we move the one Wurlitzer tremulant unit we have to the Tibia instead of
the Solo. The Solo and Solo brass trems will be OSI.
6) Acquired the required fittings, pipe and screws for tomorrows' work.
Day 9 (July 2, 2009)
1) Max finished installing the 4 rank chest bottom
2) Jack and Jerry finished the ground wires and busses for both chests.
3) All toe boards and rack boards were cleaned and rack boards were installed
4) Finished and attached the chest bearers, and replaced a missing (hole
was stuffed with a napkin) magnet for the Vox Humana chest.
5) Rudy started the massive task of cleaning and vacuuming the chamber floor.
Day 8 (July 1, 2009)
1) All bottom boards installed onto
the 4 rank chest, after replacing dead magnets and cleaning the bottom boards.
2) Installed bracing for the Tibia offset walk board.
3) Mike prepared the chest bearers for the Vox Humana chest. Again, a five
minute job turns into 2 hours due to silicone gel sealant from the
4) Turned the sound destroying center walk board into a new walk board in
Day 7 (June 30, 2009)
1) All toe boards installed onto
the 4 rank chest, after repairing gaskets and filling unused screw holes.
2) All bottom boards installed on the 3 rank chest, along with exchanged magnets
replacing the two dead ones.
3) Installed the two blank off plates on the Tibia chest
4) Started to install the Tibia winding
Day 6 (June 29, 2009)
1) The Solo 4 rank chest is up on its new legs and secured to the
2) Installed the braces for the center walk board
3) Repaired a few toe board gaskets for the 4 rank chest
4) Jack replaced some dead magnets on the Tibia chest
Day 4 (June 25, 2009)
We accomplished a lot today, and we had a large, enthusiastic
crew on hand as well.
1) Clayton and Rick rearranged the Tibia regulator springs to ease the new
2) Rick and Rob got the new chest bearers level and attached to the floor
3) Aaron punched out the the holes in the toe board gaskets
4) Mike and others got the new toe board gaskets glued into place
5) Mike and others mounted the toe boards
6) Rick and Rob made new supports for the Tibia offset chest walk board
7) Rick, Aaron and Clayton removed the Kinura and Vox humana wind chests
8) All the rest of the pipes from the manual chests were removed and
9) Jeanette and Luurt cleaned and vacuumed both chambers.
10) Luurt, Aaron and Charles started attaching acoustical tiles to the chamber
Day 2 (June 23, 2009)
1) Removed toeboards from the 3 rank chest, only to discover that Silicone
gel had been used to seal leaks. The Silicone had partially to almost completely
blocked the air flow from the primaries to the toeboards. No wonder the ranks on
this chest had inconsistent attack. This is why amateurs and hobbyists should
refrain from attempting repairs on pipe organs, without consulting someone who
knows how to do it. This will require stripping off the old gaskets and
Silicone goo and replacing it with new packing leather gaskets.
Day 1 (June 22, 2009)
1)Removed the French Horn chest with its chest bearers, Solo II and Tibia
2) Removed and stored the pipework from the 3 rank chest. Discovered that none
of the chests were cleated to the floor, just free standing.
Main II Regulator rebuild - 2007