The Second–Rebuild
By Patrick J. Murphy
In this second part of my series, Restore, Rebuild, or Replace, I will take up the topic of Rebuilding.
According to the 2000 American Heritage Dictionary of the English Language, the definition of rebuild is, 1. To build again. 2. To make extensive structural repairs on. 3 . To remodel or make extensive changes in.
This definition can serve as the basis for what we organbuilders must often consider when faced with a given rebuilding project. Does a rebuilding warrant extensive changes and are these changes justified? Is the instrument successful as it stands and what might be done to improve it so that it may function musically and reliably for the next several years? Depending on these questions rebuilding costs can usually range anywhere from 20% to 70% the cost of replacement. Many instruments will improve with a quality rebuilding. However, the best decision on whether to rebuild or replace comes only when an organbuilder has done his homework to identify what the problems are and to ascertain how best to serve the interests of the client.
According to noted organbuilder George Bozeman, “We should feel no qualms about rebuilding or replacing an organ which sounds passable, and is working reliably, but which is so unremarkable that any of a thousand other extant organs would do its job equally better or worse. This is why we suffer no pangs of regret when we replace the typical mass-produced electronic imitation organ, or a cheap, worn piano. So the question of the organ’s innate quality often determines its right to survive.” (AIO convention)
Let us take a most common situation involving the realm of electro-pneumatic instruments. A typical M.P. Moller organ from the 1960s, often today thought to be somewhat passé, can provide a suitable console shell, windchests, pipework and other well-constructed items that can yield creditable musical results. Rebuilding, of these components, rescaling, and revoicing or selective replacement of pipework, often result in a fresh sounding and mechanically reliable instrument without total replacement.
Recently I had the experience of viewing just such an instrument. While it did not contain the crisp choruses of modern expectations and was in need of a mechanical overhaul, the instrument in question nonetheless adequately filled the room with satisfactory results rendering it a useful service instrument. It was simply not necessary to resort to extensive changes or replacement with an electronic substitute. In this case, simply relocating the blower to a climate-controlled environment, rebuilding of the console, and replacement of the misaligned chest action were the recommended changes, allowing this organ to perform for the next 40+ years.
Conversion of electro pneumatic switching for the relay and combination actions to solid state is a common and valid procedure that will provide longevity and reliability of these critical components. Older pneumatic systems containing many moving parts and corroding contacts can be coaxed to function often only after providing aggressive maintenance. Increased flexibility and no moving parts make these systems reliable and reduce maintenance costs.
Pitman windchests are designed to allow access into areas that require replacement of chest leather that has reached the end of its life expectancy. Chrome tanned pneumatic leather has been demonstrated to provide improved longevity for pneumatic chest actions. However there are instances when the prohibitive labor costs of releathering certain pneumatic windchests may compel their replacement with electric slider or electro mechanical chests built with less perishable leather. This design of chest may also provide efficient use of space for additions or improved servicing while at the same time all but eliminate the need for labor intensive chest releathering in the future.
Most electro pneumatic organs that rely on leathered components, (windchests, bellows and consoles) usually average 40 or more years of useful life expectancy before rebuilding is necessary. In today’s world one would be hard pressed to think of any other large cost item that gives a comparable life expectancy. Asphalt roofs, furnaces, and other major cost items commonly found in churches will often warrant replacement long before a major organ overhaul is needed. Of course much of this also depends on care and environment.
The cleaning of blower rooms, maintenance and upgrading of service lighting of chambers, and mindful regulation of excessive heating and humidity can assist in extending the life and serviceability of most instruments.
It is important to remember that all well- built pipe organs are designed to facilitate tuning, servicing and eventual rebuilding.
Next in Series: Replacement