Build steps
Build steps
This chapter documents the chronological build process for the BIG ORGAN.
Each step can be updated as the design evolves.
Adjust the layout design
Adjust the layout design
Modify the layout based on test results and practical constraints.
Update drawings and measurements.
Build control box and electronics
Build control box and electronics
Create the main control box, wiring, and electronic actuation systems.
Include diagrams, pinouts, and safety notes.
Build the controls for percussion
Build the controls for percussion
Create the control interface and electronics for percussion actuation.
Include wiring diagrams and control mappings.
Build the motor and bellows assembly
Build the motor and bellows assembly
Construct the bellows and motor system that supplies wind to the organ.
Document pressure tests, flow rates, and noise levels
Create an initial layout design
Create an initial layout design
Design the organ layout to fit the chassis, including control panel placement.
Capture sketches, constraints, and initial ideas.
Expand on the design with measurements
Expand on the design with measurements
Add precise measurements and expand the design in a larger space (about double size) to allow for unexpected needs.
Record clear dimensions and reserved clearances.
Final adjustments
Final adjustments
Make final design changes based on full‑system testing.
Capture the “as‑built” layout and any lessons learned.
Mount and test ideophones
Mount and test ideophones
Install the metallophone in rough‑fit configuration and test actuation and balance with pipes.
Mount and test the percussion
Mount and test the percussion
Install percussion components for initial testing.
Check clearances, vibration, and access.
Obtain a mobile chassis
Obtain a mobile chassis
Procure a suitable the mobile chassis, such as a golf cart, tug, trailer, or whatever.
Document model, load capacity, and any initial repairs.
Obtain ideophones
Obtain ideophones
Source metallophones, glockenspiels, xylophones, etc. Construct the metallophone assembly, including bars, frame, and actuators.
Document tuning and mounting.
Obtain percussion instruments
Obtain percussion instruments
Create or restore all percussion instruments planned for the organ.
Note materials, mounting, and actuation.
Obtain pipe sets
Obtain pipe sets
Create, repair, or restore all pipe sets.
Completion criteria: all pipes are functional, reasonably in tune, and mechanically sound.
Obtain wind chests
Obtain wind chests
Construct or repair all three wind chests.
Completion criteria: airtight, valves working, ready to accept pipes.
Rough mount all components
Rough mount all components
Rough‑fit pipes, wind chests, bellows, motor, control box, and electronics on the golf cart.
Focus on access, stability, and cable/hose routing.
Test and troubleshoot
Test and troubleshoot
Perform airflow tests, valve checks, tuning passes, and mechanical inspections.
Log issues and proposed fixes
Test percussion and full system
Test percussion and full system
Test percussion alone, then test all organ components together as a unified system.
Log timing, balance, and reliability issues.