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Building a new console (96IIIP)

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

Building a new console (96IIIP)

Postby Martijn70 » Fri Apr 26, 2013 7:55 am

When time is available I work on my new console. Last year I ordered set of three manuals at UHT to kick off the building process. Progress has been slow but things are coming together now. Here are some pictures to show the results so far:

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The cheeks are made of a kind of exotic rosewood we had in storage. The thumb pistons will be engraved later. Key coverings are of mineral and blackwood.
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Re: Building a new console (96IIIP)

Postby Martijn70 » Fri Apr 26, 2013 8:04 am

Building the case of the console. I used mahogany for the case, the pedalboard is of oak with rosewood covering for the sharps:

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Re: Building a new console (96IIIP)

Postby Martijn70 » Fri Apr 26, 2013 8:16 am

The stoptabs are made of left overs, but are of precious ebony :D

On the left the ''example stoptab" by Heuss.
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After cutting and routing a lot of sanding has to be done:
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Cut them in two:
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Cut them to the actual size:
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Done:
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Re: Building a new console (96IIIP)

Postby Martijn70 » Fri Apr 26, 2013 8:29 am

Had the thumb pistons engraved:
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Filled them up with a 2 component resin:
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After sanding:
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The layout:
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Re: Building a new console (96IIIP)

Postby Martijn70 » Fri Apr 26, 2013 12:58 pm

Making the oak stop tab jambs:

Eight separated stop tab blocks:
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Having a slope of 60 degrees:
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Blocks assembled:
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Fitted into the console, the stop jambs have a 10 degree angle with the manuals:
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The name board installed, later several switches and a LCD will be fitted into it:
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Top manual rail fitted:
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Assembling the switches into the stop tab blocks:
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Later these switches will be covered by the ebony stop tabs, made before.
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Re: Building a new console (96IIIP)

Postby RichardW » Fri Apr 26, 2013 1:40 pm

From your profile:

Username:Martijn70
Occupation: Organbuilder

I have to say it shows. The console looks wonderful!

Regards,
Richard
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Re: Building a new console (96IIIP)

Postby Martijn70 » Fri Apr 26, 2013 4:16 pm

Well, I can use the workshop, that a plus for sure. Even some of the wood is for free (the ebony for the stop tabs). There are some financial limitations, so I have to use a cheap stop switch solution. But it works perfectly and looks far from cheap in the end.
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Re: Building a new console (96IIIP)

Postby Roman » Fri Apr 26, 2013 5:01 pm

Amazing woodworking skills. I admire your devotion to every detail.
I especially love your idea of making the letters/numbers in the pistons. Surely I'm gonna use it someday if you don't mind.
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Re: Building a new console (96IIIP)

Postby engrssc » Fri Apr 26, 2013 8:46 pm

Admiring your work. Couldn't begin to do that caliber of wood working in my shop.

Several questions: How did you cut and fashion the ebony stop tabs? Are they going to be labeled? Are those holes above and below the stop tabs for ventilation? And finally, what are you using for (the electrical part of) the stop switches?

Rgds,
Ed
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Re: Building a new console (96IIIP)

Postby pat17 » Sat Apr 27, 2013 12:17 am

Quite an impressive work! 8)

Thanks for sharing the details of your console's construction. It helps to figure out how much work and attention is required before arriving to such a result.

I guess you must be very impatient to play it, after months and months working on it. :wink:
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Re: Building a new console (96IIIP)

Postby Andrew Grahame » Sat Apr 27, 2013 4:34 am

Hi Martin,

This is wonderful! Clearly you are at the other end of the food chain from me when it comes to woodworking skill. I am in awe of anyone who can create a masterpiece like this. May you derive immense pleasure from playing this organ when it is completed.

Andrew
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Re: Building a new console (96IIIP)

Postby Alexander_K » Sat Apr 27, 2013 4:45 am

Excellent work!
Cogito ergo sum.
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Re: Building a new console (96IIIP)

Postby Owen Jones » Sat Apr 27, 2013 4:46 am

Very nice work; I wish I had your woodworking skills.

all the best
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Re: Building a new console (96IIIP)

Postby Martijn70 » Sat Apr 27, 2013 4:51 am

Thank for all the compliments! I hope to get all things done by the summer and finally enjoy playing it.

roman wrote:I especially love your idea of making the letters/numbers in the pistons. Surely I'm gonna use it someday if you don't mind.


I don't :D At our company it is the only way how we do thumb pistons.

engrssc wrote:How did you cut and fashion the ebony stop tabs? Are they going to be labeled? Are those holes above and below the stop tabs for ventilation? And finally, what are you using for (the electrical part of) the stop switches?


We used a fixed axis milling machine for the radius cut-out in the stop tabs. I can label them but I haven't decided yet, changing stop names is an issue yet to be solved. The holes in the pcb's have no ventilation function, the switches are soldered, as will be the wiring for the LED's and connections to the LITSW boards. These pcb's are normally for experimenting, and have therefor all the holes. I painted them black to cover them up, but they will be difficult to see since the stop tab will have only a 1.5-3 mm clearance. For all the pistons and stop tabs I will use boards from Roman's midi-hardware.com (4x LITSW, 1x MRG2, 1x BBSP, 1x MiDisp, manual and pedal uses UHT's midio4).

regards,
Martijn
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Re: Building a new console (96IIIP)

Postby florianf » Sun Apr 28, 2013 9:08 am

Your console really looks impressive! Your woodworking skills are superb. I would love to play on a console like that, but the cost of making something like this would probably consume all my savings when hiring someone to do the work.

Concerning the problem of changing the stop names at a regular basis, a German organist made an interesting suggestion a few weeks ago in another forum: Why not use small E-Ink Displays(like those Kindle displays)? In my country these are already used in supermarkets in order to quickly change the prices for all chain stores at once (and whats more, they can be controlled 'over the air' via wireless transmission), so they must already be quite cheap. If somebody comes up with a way to control them efficiently, we might even be able to switch them automatically when loading sample sets, perhaps in Hauptwerk v.99 or something like that :lol:
It would clearly take a lot of work to figure out efficient solutions concerning the wiring and control, but with the amount of organ-loving engineers to be found here, we might be successful eventually.

Regards,
Florian
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