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Building a New Console for Myself

Share photos of your Hauptwerk consoles, installations, audio systems, ...

Building a New Console for Myself

Postby dw154515 » Tue Oct 15, 2019 11:13 pm

I recently bought myself a Shapeoko3 XXL CNC router. I've had a lot of fun playing with it and getting to know it, as well as learning the basics of CNC machining - it's a new world to me. So far this week I've been experimenting by building key cheeks for my 6 "new" (to me) Fatar manuals.

I practiced with some scrap pine 2x4's today and will be heading to a local lumber company in the morning to pick up my new curly maple 2x4's to start building the real deal. I'm thinking about how I want to do the console top. I am really wanting to do that "live edge" look. Why not? I don't recall that ever being done on an organ console before, so it sounds fun.

Something like this:
https://images.app.goo.gl/H23CR5jsoNRztAzYA

I've also seen a beautiful modern-looking Hauptwerk console made mostly from brushed stainless steel, maple, and glass. I LOVE that look. I'm not sure if I want to close in the base to hide everything, or go for that sleek modern look.

Anyway....

I figured I'd share this with the community in the hopes that someone will get some inspiration from it.

Also, I would like to mention that it takes about 30 mins for me to make a pair of key cheeks for Fatar TP6/TP60 manuals. If anyone is interested, I might be willing to make them for folks for a reasonable price if time and resources are available.

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Here is a link to a video that should be available to the Public.
https://www.facebook.com/composerdrewworthen/videos/10100980744987512/
Drew A. Worthen
Master of Music in Composition - Butler University
http://www.drewworthen.com
Director of Music - Greenwood UMC
http://www.greenwoodumcmusic.org
Field Engineer - Sensory Technologies
http://www.sensorytechnologies.com
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Re: Building a New Console for Myself

Postby voet » Wed Oct 16, 2019 12:38 pm

Nice work, Drew. Be sure to post pictures when you have the live edge work done. I think this could result in a really unique and stunning design.
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Re: Building a New Console for Myself

Postby 1961TC4ME » Wed Oct 16, 2019 3:29 pm

I think the live edge would be neat and give a very unique look!

CNC is very cool! I assume you picked up an entire package, CNC table and gantry, or did you buy just the gantry and make the table yourself? From the pics I can see, it looks like you got both which is the best way to go so everything works correctly. I've been looking at doing the same but am very interested in a CNC table and plasma cutter (which is also very cool!) I'd imagine with a bit of ingenuity a person could adapt a router to it as well like you've got.

Do you have it connected to a lap top with a program where you can plot out the pieces with? If so, which software?

Marc
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Re: Building a New Console for Myself

Postby johnstump_organist » Thu Oct 17, 2019 7:56 am

My experience with maple is that it chips and splinters easily. You may want to be sure to go slowly and make several shallow passes at first in order to avoid chipped edges.
John
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Re: Building a New Console for Myself

Postby dw154515 » Thu Oct 17, 2019 9:54 pm

1961TC4ME wrote:I think the live edge would be neat and give a very unique look!

CNC is very cool! I assume you picked up an entire package, CNC table and gantry, or did you buy just the gantry and make the table yourself? From the pics I can see, it looks like you got both which is the best way to go so everything works correctly. I've been looking at doing the same but am very interested in a CNC table and plasma cutter (which is also very cool!) I'd imagine with a bit of ingenuity a person could adapt a router to it as well like you've got.

Do you have it connected to a lap top with a program where you can plot out the pieces with? If so, which software?

Marc


I built the table and plexi-glass enclosure myself, as well as the motorized lift/hood. I spent the first couple weeks learning how to use the machine by building little mods and add-ons for it - including an adjustable laptop stand, etc. The plexiglass enclosure helps keep the noise down and dust under control (with the vacuum dust boot helping in that area as well). To my understanding the Shapeoko seems to be quite "hackable" in that you can really use the gantry to do pretty much anything you want - lasers, etc. I don't know if anyone is currently using it for plasma. I have considered the laser options, though. That could come in really handy for engraving. As for software, I did these in the free software that comes with the machine from Carbide Create. Their CAD/CAM software is very basic, but for the sake of making some keycheeks and stop jambs, it will work just fine. I do have Fusion360 but haven't gotten into learning it yet, though.

johnstump_organist wrote:My experience with maple is that it chips and splinters easily. You may want to be sure to go slowly and make several shallow passes at first in order to avoid chipped edges.
John


Thanks for the tip. Luckily the Shapeoko will auto-calculate feeds and speeds based on a few parameters - such as wood species, bit size, etc., so that takes a lot of the guesswork out of making sure I don't ruin a good piece of wood. (Still, though, I made sure to buy extra! Mistakes are inevitable.) I grew up doing a little bit of wood working - certainly nothing "furniture grade" so working with some exotic woods is very new to me. True, Maple isn't really "exotic" but it is new to me for sure. The lumber company I like going to (Northwest Lumber Co. in Indianapolis) has EVERYTHING from California redwood to Zebra wood, curly cherry, mahogany, Bolivian rosewood, Cocobolo.... you name it. They have a lot of bare slabs to chose from too, including a 4" thick, 96" tall, 48" wide slab of California redwood (for $9,000!), but oh my it is BEAUTIFUL! I looked at a lot of their live-edge Maple slabs and told them exactly what I was looking for - something that curves INWARD SLIGHTLY near the center, rather than outward. They said they would call me if they got anything in that fit the description. I told them I was making an organ console, and one of the ladies showed me a bunch of old wooden organ pipes that she recently found at a flea market that she was quite enamored with.

Here are some pictures of the new maple key cheeks. They came out BEAUTIFULLY!

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Hi Res versions:
https://i.ibb.co/nBPcbzm/IMG-1428.jpg
https://i.ibb.co/P6YpLhk/IMG-3795.jpg
https://i.ibb.co/gRYwc8B/IMG-3902.jpg
https://i.ibb.co/TrR3Zck/IMG-5468.jpg

The first set of cheeks got a coat of high gloss Waterlox today, which requires 24hrs of dry-time between coats. That should give it a nice bright sheen. It really makes that maple POP!
Drew A. Worthen
Master of Music in Composition - Butler University
http://www.drewworthen.com
Director of Music - Greenwood UMC
http://www.greenwoodumcmusic.org
Field Engineer - Sensory Technologies
http://www.sensorytechnologies.com
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Location: Indianapolis, IN

Re: Building a New Console for Myself

Postby dw154515 » Sun Oct 20, 2019 3:31 pm

More pictures:

Already practicing how to do the piston rails.
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All the new maple cheeks. The one on the bottom has a couple of coats of Waterlox, which they will all get eventually.
Image

Links to hi-res pictures:
https://ibb.co/7Q03fnc
https://ibb.co/w6D0tZQ
https://ibb.co/pK9cFNp

So I discovered that not all Fatar 10P6/60 manuals are exactly the same - this was news to me. I should have measured ALL 6 of them. I purchased 2 sets of 3 from two different people, and never took all of them out of the boxes to make sure they were all the same. Come to find out, one set of three is ever so slightly different from the other three. One is the heavier tracker-feel. And the other is a bit cheaper feeling. It appears the Fatar chassis is the same on each, but the key thickness, and dimensions are slightly different, so back to the drawing board on those, I suppose. (Top most manual in the four manual stack, pictured.)
Drew A. Worthen
Master of Music in Composition - Butler University
http://www.drewworthen.com
Director of Music - Greenwood UMC
http://www.greenwoodumcmusic.org
Field Engineer - Sensory Technologies
http://www.sensorytechnologies.com
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dw154515
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Posts: 280
Joined: Mon Nov 12, 2012 2:52 pm
Location: Indianapolis, IN


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