Hjem Home digital organ Organ related Building a console - Console page 3
Building a console - Console page 3 Print E-mail
Written by Vidar Fagerjord   
Saturday, 24 July 2010 00:04
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Update 01. september 2010

Today I made some progress on the framework. I made a rectangle-shaped frame for the upper part of the cabinet. It will help me during testing of the concept too. But first, let me show you a couple of details.

In the image above, you can see the 45 degree bevel I routed where my feet will move about. The bevel extends just outside the keyboards. From the point where the bevel ends in the image above, towards the front sidewall, I plan to mount a drawer for a keyboard and perhaps a mouse - crucial for when you need to do some work on the computer that lurks inside...

Another shot that shows the bevel. And you can see the "coffee cup tray" on the right side.

Here's a shot of the bolt that secures the "ladder" to the side panels. It is countersunk using the router (hence the somewhat irregular shaped hole).

And now for some exciting images - the console as it stands now! First up is an image showing the "ladder" and the top frame. I haven't made any mounting options for the frame yet, but me clamps is holding me together...

Next up: an image showing a mock-up of the side panels for the pedals and the keystack:

The interior will be in natural color. The idea my dad had about keeping the framework natural and just the side panels stained dark proved to be brilliant! At least for my taste.

And the last image; A shot of the panel on the right side of the keyboards:

The panel will hold the touchscreen on one side, but I am considering another touchscreen on the other side as well. If not, I'll find something to put there...

That's all for today. Tomorrow I will continue work on the upper frame, and perhaps mount the thing in my living room together with the keystack and the pedalboard to get an idea of how this will end up.

Update 04. september 2010

Wow! The autumn is clearly on its way - pretty cold outside, and the mountains surrounding the fjord got a light drizzle of snow some days ago! Yet the forest is still green, but that won't last too long. Perhaps it is a hint for me to bring out the score for Vivaldi's four seasons? Anyway, on to the organ building business.

I moved the console parts into my living room for a little testfit of all the components. WOW! This thing is going to be perfect! The height of the keys are now perfect, and the pedal board is correctly placed - the playing experience is far, far better! Not to mention that it looks awesome!

The next task is to make the jambs on both sides, the back wall behind the keyboards and the panels around the pedal board. Here's two pictures of the beast:

Here's a picture that gives you an idea of how the area around the keyboards will look like. The right side will be empty, and the touchscreen will be mounted on the left side. I am considering another touchscreen on the right side, but that is not a priority. I might just end up mounting switches for the stops (voices) on the right jamb...

You can also spot the "roof" over the keyboards, near the top of the image. I used the router to create a dado/groove around the edges of the framework, and cut a plywood panel to size. It will be secured in place using screws. On the underside , the framework creates an edge around the "roof" so that I can mount a hidden light for the keyboards (will avoid glare).

The music stand will be mounted to the back wall using keyhole hardware (a piece of metal with a keyhole in it; you can hang it on a screw). This enables me to do a lot of things should I decide to add a row of coupler switches under the music stand - or even install a fourth manual.

And finally, a picture of the whole setup. In addition, there will be a 60 cm high case on top of what you see in the image, and I'm going to mount real pipes at the front. More on that later on.

It was a good idea to do a test fit like this - it gave me a few ideas, created a few issues and it gave me a GREAT boost in motivation! Can't wait till this thing is completed!

The only thing that can't be fitted into the console is the subwoofer. Perhaps I should make a Rügpositive and place it behind the bench? Perhaps I should build a bigger house first...

Here's the Google Sketchup file for the console. Use at own risk! Remember that any measurements are related to my specific setup; you might need to do some alterations.

Update 11. september 2010

Todays update is dedicated to the memory of all the people who perished in the attacs. We will never forget!

Back to organ related business: The top part of the console is on its way, and some other areas have gotten some attention too. The side walls on each side of the keyboards must be fastened somehow, and since I want the whole thing to be IKEA-style (meaning that it can be disassembled should the need present itself), I made a rail for the plywood sheet on which the sidewall will rest. At the top I'm going to screw the sidewall in place. The rails was made from solid oak which I routed a 10mm rabbet (the plywood is 9mm). I then drilled and countersunk holes for screws. I then glued and screwed the rails in place. Kind of overkill really, but I needed the practice anyway. I could've just glued and used 3-4 clamps. On the other hand - glue + screws equals rock solid. So why not?

Here's a detail shot of the rail:

The screws I had lying around was a bit too short, so I had to countersink rather deep. Should not matter anyways... And here's the concept demonstrated:

I am going to add solid wood banding to the plywood sidewall, and the stop jamb will be mounted flush as shown in the image (although hopefully a bit more "exact" fit...).

I also started work on the pedal board "house", but unfortunately I forgot to take pictures. That is bound to happen when I have my iPod loaded with woodworking podcasts and listening to them while working... However, I've only made a few plywood parts. Nothing fancy, really. I'll post images as soon as I get more work done on that area.

As you might have guessed, the console was disassembled and moved back into the shop. The next part was the top of the console. I decided to make the console with a removeable top part should I ever need a lower console. I made the bottom frame earlier, and started by fastening the roof over the keyboards. Plywood tends to bend a little when stored upright, and the roof part was no exception. I routed a rabbet around the center opening in the frame and cut a piece of plywood into shape to fit into the rabbet. The rabbet is 15mm, and I wanted to use screws and glue to secure the roof in place. The screws are placed at the center of the rabbet. I measured ~7mm from the edge of the rabbet and marked a line around the perimeter of the roof plywood. I then used a neat tool to mark the location of the screwholes: a compass with a pencil holder. I adjusted it so that the legs had the desired distance from screw to screw, and the rest was childs play. Here's a few images to clarify:

I used my beloved large square to trace the center line of the rabbet, the caliper was used to measure the distance and the compass "walked out" the markings for the screwholes. FAR more easy than measuring with a tape measure! Get the point?:

Here's an image of the rabbet (no, a rabbet is not a bunny's larger cousin!):

The center lines for the rabbet can be seen, in addition to some markings. The rabbet was routed using a rabbet bit with interchangeable ball bearings. It was routed in no time! I've invested in a professional grade router, the Bosch GOF 900. Fantastic tool! At the same time I got some other smurf tools (meaning the professional series from Bosch, which has blue color. Green is for noobies! ):

It is a pure luxury having more than one drills! And including my father's green Bosch (one need to distinguish oneself from the older generation!), I have three. Spoiled? Yeah, and I love it!

All kidding aside; the smurf-drills wasn't placed there just to brag. The large one was first uesd to drill the holes, then to countersink them. Then I used the smaller one for the screws. I'm trying to include the tools I'm using more, so that people with little experience can get a clue what I'm talking about. Not that I'm a skilled craftsman or anything, but I'm starting to get quite a bit of knowledge about woodworking. I had very little from before I started this project...

Back to the top of the console. Here's the completed framework:

It is constructed in the same manner as the lower console. All the parts are fastened to eachother using dowels. The next step is to disassemble it, route a dado for the panel inserts in the sides, make the panel inserts and stain them brown, then glue everything up. Then I have to make the roof using the same method as the roof above the keyboards (a plywood piece inserted into a rabbet), and the back wall (using thinner plywood). The real organ pipes (non speaking) will be mounted in the frame, in front of a speaker fabric screen.

And here's the console top placed where it belongs:

It is starting to get big...

Bonus: you can spot the start of the panels surrounding the pedal board! As for the tools: on the left side is my dust-collector (a vaccuum-cleaner on steroids!), and below the center: my planer/thicknesser combo machine. The brown thingamabob is what's keeping me warm...

As you probably can see, the shop I'm working in is rather small. But a bit of planning helps a lot. If I had a larger shop, I could've done more work in less time, and it can be frustrating having to lug the heavier machines around - especially when you discover that you forgot to run that last part through the thicknesser...

But - it is a hobby, and it is SUPPOSED to take up a good chunk of my spare time. The reward: my own, self-built digital pipe organ! And if you wander: yes, I've thought of making my own keyboards too. I plan to leave it at that.

Last Updated on Wednesday, 04 March 2020 08:16
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