welcome to present up your program for the performing arts crescendo was a production of international artists in new york city and c n n washington thank you for joining us we're going to go back to the pipe organ manufacturing company triborough that actually makes organ pipes we are going to see an organ pipe made from the very beginning to the end as a matter of fact the pipe that we're going to see happens to be this very trumpet pipe on the organ here now i know that's a little different appearance than you were accustomed to in order of pipes most people when they think of an organ pipe they think a pipe that looks like from all different shapes and sizes and we're going to show you how they're made i have here with me a gentleman by the name of joe cliff and joe is one of the partners in tr to him let's go inside you see what you have to show us with no problem in the first step in the creation of a pipe organ is the pouring of the block you see here four different molds that are going to be used for different types of organ pipes now lead is used to create the block and i need to be skimmed off of all impurities which you can see lendl doing right now in order for the block to work properly you have to have specific holes for the air and fo tuning this bigger pan is for the shallot which you will see created later on and the smaller one with the handle is the tuning pan now the lead has to be poured into the mold and it will cool rather quickly and change color and this will later be laved to be the correct size and fit which we will also see in just a moment now watch very carefully as the lead cools you will see a change color will get a little bit lighter and all separate pipe for every single musical tone so on a keyboard that sixty one notes long there actually have to be sixty one individual pipes and each one graduated in know the next thing we need to do is heat the mold for what is called the toe of the boot now these are the two parts of the mold you put them together and he is now ready to pour the lead into the mold you can see a completed toe in front of the mold there it is not perfect it has some a secondary one once the lead has cooled he is able to remove the toe from the mold it doesn't take very long for the lead to cool enough to be to be able to be handled because it sets pretty quickly so now he has completed a much better mold of the toe and this is one that we will use to take to the layers to prepare to put on the boot now the toe is completed we return to the same lathe charlie was using a moment ago to lay the toe to the correct size to be used for the bit as joanne market mentioned earlier you need one toll for every single note of an organ stop so here you see a complete set of toes that are going to be used on the after cutting the opening alan is now going to have to solder and in cap on it so he lights the torch and here we see a flat square in cap being soldered on to the show lot the corners of this are going to have to be sheared off he'll take it over to the shear shear all for all the corners and now take it to the sander and very very smoothly polish every part of the outside of the shell lot until it looks like one solid brass  piece a real craftsman will now show us how to make a spot of metal bell and his inkstand for one of these  year what we're seeing little do here on this years is cut the stem you can only cut the straight edges because the right is not designed for rounded edges he has to use a scribe tool which we will see in a moment to carve out curved edges and do that by hand good enough you can just take  with the pattern and do pretty much the same thing and now we are again on the cutting of the bell and he takes the scribe tool again more has to cut both ends of the bow since the both the top and the bottom part of the belt are current and tool is necessary as i'm sure you can imagine it takes a very steady hand to be able to stay within the lines of the current to make sure that you do not go outside of it because you do need to get a clean cut now with the middle firmly in place he is able to shape the stem of the pipe to be more exact more round this will allow them to be able to solder t o pieces of the pipe together now what lundell is doing is putting some masking paint on the both pieces of the pipe on the stem and on the bell this is the area where they don't want the solder to affect the metal this will make it so that the metal does not receive the heat therefore when they scrape it like is being done now where the scraping is done is where the solder will go and that will then make a perfect scen now both sides of each opening need to be scraped in order for the solder to attach to both sides to form a weld down the two pieces of the bell as i'm sure you can tell this does take a very steady hand and look at what a perfect seam is create one solid seam all the way up the entire stem and here we have a completed stem and now both of these need to be prepared to be soldered together so we have to create a flush surface on both ends where the soldering is going to come together after soldering those together the end belt together now the paint has been applied to heat resistant paint has been applied to both sides and now he will tack the two pieces together and then create his solder now he is using the same it as before using the gas heated soldering iron he finishes the complete soldering join t yet now we're going to go over to the drill press where lendl clip joe's son is working very steadily on putting a perfect depression in the lead block to except solder a small brass furrow all has to be fitted in and soldered perfectly into these depressions now the brass has to be completely polished so that it will have a very shiny surface and a very open surface for the solder to stick to he cleans one side and then turns it around the drill press and uses the emery cloth to clean the other side will go over to the actual block where the soldering is done now here we see the torch and we see lendl setting some tacking points and then he will very quickly just use his iron to add solder in a wonderful puddle that  the smaller pipes need that brass for which was all and just solder this trumpet pipe is a little larger so it gets hotter directly into the block which we will see lendl doing now leaving the paint that was used to keep the solder from sticking to the pipe when affect the way the pipe sounds when it is played so charlie is now taking a solution and cleaning it off before the pipe is lacquered that stuff  his lacquer spray and we need to do this in a well ventilated area that's why we see the family time and it has to be done in several coats has to be sprayed and then we have to let it dry and we need to separate again now the first coat has dried we are now applying the second coat to the pin now joe is going to insert the shell of the tongue he created into the board what you saw support the beginning of the show has to be aligned properly and the tongue has to be set in properly so you have to make sure this is exact for years here and we just put it down into that belly area and start from the back and rub the curve forward put more pressure as i go forward with it even though it doesn't look like it but tongue needs to be flush with the top of the shellac and it will pour just a fraction as you're as you're driving you don't want to drive it overly much but good in snow to keep the and then you check your tension it needs to be good and square like a teen as it rides up and down on the face of the tom to one foot see so it would be eleven inches so we're just  great and it's too bad that so much of this is getting lost today because this is a wonderful shot it is one hundred percent totally american and it in seattle have parts made in this very shop by the private company thank you for joining us on this episode of crescendo we hope to see you next time