DIYAPASON-L Digest #636 - Tuesday, September 3, 2002
Toe board?
  by <>
Re: [Residence Organs]  Toe board?
  by "Nelson Denton" <>
Re: Toe board?
  by <>
Re: [Residence Organs]  Re: Toe board?
  by <>

(back) Subject: Toe board? From: <> Date: Tue, 3 Sep 2002 10:22:06 EDT   Hi all, I was wondering what to make a 22" wide toe board out of? This is the first of three choir chests. Thanks Dennis  
(back) Subject: Re: [Residence Organs] Toe board? From: "Nelson Denton" <> Date: Tue, 3 Sep 2002 13:07:29 -0400   There are several ways to do this. One is to use solid core plywood = without voids! I laminate the sheets together to thicken them up, however it does make for a heavy chest.   Another option is to join several planks together one, for each row of pipes. You might choose to drill all holes - rackboards first then assemble. Many builders drilled a hole in the ends of the planks to allow = a long threaded rod to pass through from one side of the chest to the = other. This helped to keep the wood from splitting as it moved. The main difficulties of making wide chests is the complexity and physical size of the chest ( trust me it's easy to make a mistake in sizing when = your drilling 500-2,000 holes), and the problems of shrinkage/expansion of = wood. Really good dry wood is hard to find now and the stuff from your local lumber yard just won't do it. You won't find clear 22" wide lumber stock much any more :-((   Remember a two foot wide chest gets heavy quickly and will be difficult to manage in a small shop.(can you get the chest past doors and hallways and into your chambers?) Also drilling holes in a wide board is difficult if = you don't have a radial drill press with a DEEP throat depth.   There really are reasons why organbuilders make chestwork for single = ranks as well as multiple ranks.   Plan carefully and think of all options first then start cutting :-))     > Hi all, I was wondering what to make a 22" wide toe board out of? > This is the first of three choir chests. > Thanks Dennis      
(back) Subject: Re: Toe board? From: <> Date: Tue, 3 Sep 2002 14:37:48 EDT   Dennis:   You did not say how long the toe board was to be. Traditional pines, = Pinus strobus L., Pinus monticola Douglas, Pinus ponderosa Douglas, etc., rarely =   are found in such widths as 22" today and sugar pine, Pinus Lambertiana, = has gotten somewhat expensive as logging in old growth regions has stopped. I =   prefer to use 8% or less kiln dried poplar which I can get through a local =   connection. Poplar, Liriodendron tulipifera, is a crop tree that is designated as quartersawn and is the finest wood you can use at a = reasonable price without going to a cheaper plywood. It is easy to work and the = burned toe seat bevels are smooth as glass when done correctly. An amber shellac =   finish on the wood looks like a million dollars. However, a word of = warning, unless you have dealt with the specialty lumber supplier before and trust them, double check all wood that you purchase with a moisture meter and inspect the lumber very carefully. Few suppliers know the requirements = for those of us who make airtight furniture!   You did not say what kind of chests you were building. If it is just a direct electromagnet type then any voidless plywood will work just fine = and be relatively inexpensive.   Another item to consider is how much weight will you have on the toe = board. At 22" wide putting heavy pipes in close planting will put a lot of weight =   into a small space. You will have to take the load bearing of the toe = board into account if that is the case.   For a more complete discourse, check out my Organ Building 101 article on wood in The Glue Pot in 1997. I understand it has been put up on the Internet somewhere but have never found it. It is also a definite sleep = aide to be sure. ;-)   Al Sefl  
(back) Subject: Re: [Residence Organs] Re: Toe board? From: <> Date: Tue, 3 Sep 2002 22:25:51 EDT   I am a little slow Monday type mornings. The chest is 8' long and is going = to be an Austin like action. Look at the picture on the web site of the great =   chest it will be very similar. It will be 4' c on up, a dia., Ludwig, free =   read claiernet & wood flute. The 8' pipes are on an off set, dia. free = read and flute, I thought for the Ludwig I would use the flute for the bases. = What do you all think? Poplar is the wood of choice I. I have a rough wood supplier who sells all kinds of wood that I can buy from, it takes time to = go down there but you can find really good boards IF YOU LOOK FOR YOURSELF. = That is the best way I guess. Thanks for the help. Dennis   R