New organs.
Creating a new pipe organ is a harmonious blend of artistry and precision engineering, requiring superb attention to detail and a broad understanding of both musical and spatial dynamics. From the initial design phase to the final installation, every step in the process is guided by Greenleaf’s commitment to excellence, and our appreciation and reverence for the centuries-old tradition of organ building.
The first step towards new slider windchest toeboard construction: this slab will ‘rest’ for four months before use.
Designing a new organ.
The design for a new organ is a synthesis of many elements that must be considered. At the core of the process lies a deep understanding of the client's musical and tonal ideals, and the intended use of the instrument. Many factors play a crucial role in shaping the organ's design such as the size and acoustical volume of the space, the nature of the liturgical, ceremonial, and musical activities that occur, as well as the available area for installation.
Additionally, the visual integration of the organ with the surrounding environment, whether blending in seamlessly or standing out intentionally, is carefully studied.
Choosing the right action.
One of the pivotal decisions in organ design is selecting the mechanism that will govern its operation. This a critical decision, one that impacts not just playability but also the overall character of the instrument.
There are two broad types of organ mechanisms: mechanical and electric, or electrically assisted. Mechanical action offers a direct physical connection between the keys and the valves controlling airflow to the pipes. This intimate connection allows for a feeling of nuanced responsiveness that many organists cherish. The touch is often described as ‘definitive’ or ‘crisp,’ providing a sense of immediacy and control. However, the space available, overall tonal concept, wind pressure, and complexity of aids to playing may preclude the use of mechanical key or stop action.
Electric or electropneumatic actions, on the other hand, utilize electrical signals to transmit information from the keys to the valves. This approach offers greater flexibility in design, allowing for larger organs, movable/remote consoles, and more versatile use of a given number of ranks. Electric key actions can be designed to provide a variety of touch sensations, approximating the feel of tracker key action, or offering experiences tailored to a particular style. Ultimately, the ideal sensation of playing is one that is natural, offering the most intimate connection between player, music, and instrument.
The choice between tracker and electric actions isn't always clear-cut. Instruments incorporating elements of both offer a blend of responsiveness and flexibility, allowing for a larger instrument with a more nuanced touch. The decision ultimately hinges on several factors, including an instrument's tonal concept, size, musical function, and available space.
At Greenleaf, we are at home working with a number of action types, allowing us to find the ideal artistic match between the instrument, the space it inhabits, and the musical goals of our clients.
Image shows new pouchboards for electropneumatic windchests receiving their leather valves.
Constructing a new organ.
Construction of a pipe organ starts with the selecting of materials and employing modern technologies. Most organ design at Greenleaf is achieved using advanced software (REVIT by Autodesk) to create detailed 3D models, allowing for superior coordination with architectural plans. This software is industry-standard to the building, design & construction industry, and provides for easy interfacing of new organ design with similar models of a new or existing building. Solid hardwood and structural steel form the backbone of organ structures, while casework is carefully chosen to complement the building's interior. Wood is milled from rough-sawn lumber to custom dimensions and traditional hand tools coexist with state-of-the-art CNC routers, ensuring both precision and artistry in construction. Wood pipes can be made from a variety of wood, including poplar, fir, mahogany, or walnut. Metal pipes are constructed of alloys, that include lead and tin with antimonial content to provide material that is sufficiently malleable and ductile in order to allow fabrication and voicing to achieve the desired tonal characteristics while also providing for long-term structural stability within a given pipe.
For any rebuild project, we use advanced technologies such as CNC routering, which allows for precise milling of drawing files to exacting standards. Furthermore, we employ state-of-the-art solid-state switching and control equipment from reputable companies in the organbuilding support industry. These technologies enhance precision and reliability while ensuring ease of maintenance and availability of replacement parts in the future. While organbuilding is heavily reliant upon centuries-honored materials and processes, we are careful to adapt new materials where the use of these can result in greater long-term reliability, or to use traditional materials in innovative ways.
Image shows the 'inner workings' of an electro-pneumatic slider windchest.
Installation process.
Each organ is fabricated, constructed, and completely erected in Greenleaf’s own workshop for testing. All constituent parts are labeled and cross-referenced. Then, the instrument is completely disassembled and packed for shipping and transport to the installation location. Upon arrival, the organ is re-erected over the course of several weeks or months by Greenleaf personnel. Following the installation and testing of the instrument in the client’s location, the instrument is custom-voiced by our voicing experts. Each pipe is individually checked and adjusted for a tonal finishing of the instrument in the space which is hand-in-glove to the acoustical environment.
The design, construction, and installation of a pipe organ is a labor of love and requires a unique blend of craftsmanship, artistry, and technical expertise. From the initial considerations of space and client preferences to the final installation process, each stage reflects the dedication the Greenleaf team devote to every new instrument in our care.
Image shows a new two manual and pedal console in mahogany.