Busker Building Hints

by Jim Bryan

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First of all, a big "Thank You" to John Smith for his work creating this very satisfying project that has allowed many of us a somewhat simplified launching pad into organ building that some of us might never have tried, due to the overwhelming complexity of traditional designs. While challenging to a degree, it was a very attainable and rewarding goal which was full of things to learn that will be helpful on future projects. I am very happy with the outcome.

Bellows Hints
I used Formica laminate for the stiffeners. I obtained a lot of free scraps from a countertop maker. It is very rigid and thin (1/32") and has a rough back for glue adhesion. Being very thin allows the bellows to fully close properly. The edge must be sanded to remove the sharp edge that would quickly cut or wear through the bellows cloth. I used blackout curtain material, using PVA Glue to attach the stiffeners.

I used a hot glue gun to attach the cloth to the wood pallets. The glue sticks were the slower hardening woodworking type and seemed to work rather well, but I still had to keep moving quickly, gluing about 3" at a time and getting it pressed down before the glue cooled too much. I also used Clear Silicone Sealant to seal leaks that I found while testing the bellows function.

Music Roll Guides
I used ¼" dia. Carbon Fiber Arrow Shaft for the Guide Rods on either side of the tracker bar. This material is extremely rigid and smooth and lightweight, and provides a guide that is easy on the paper and will not flex at all.  It is sold at Sporting Outfitters and is also used as Kite Sticks and R/C Airplane pushrods and can be found at Hobby Shops.

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