Here are some photos of the pipemaking and voicing process

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Gebruder Kas pipemakers

These photos were emailed from the pipemaker Gebruder Kas in Bonn, Germany. They made my new Principal and mixture pipes along with some pipes to complete my 2 2/3 and 1 3/5 ranks.

the cylindrical portions of the pipes are made, notice there are no mouths on the bottom of the pipes

soldering the seam on the pipe soldering the seam of the pipe body. this can be difficult, the metal is soft and easily melted
Toni Kas solders languid on the pipe toe Toni Kas solders the languid(divides the toe and body) onto the toe of the pipe.
Toni solders toe to pipe. Toni solders the toe to the body of the pipe.
pipes arrive from Germany this is the 2' Principal Unwrapping the new pipes from Germany, this is the 2' Principal
the new mixture pipes from Germany New pipes that make up the 2 rank mixture
new spotted metal 2 2/3' bass pipes New bass pipes to complete the 2 2/3' rank. This is a good example of spotted metal. It is often used in pipemaking. The spotted appearance comes from the ratio of tin to lead and the size of the spots varies accordingly. These pipes are about 52% tin and 48% lead.
4' Principal pipes are 70% tin 4' Principal pipes were made with 70% tin and about 30% lead which gives a more uniform shiny appearance. The higher percentage of tin gives a brighter sound often used in Principal pipes and mixtures. It also has a nicer appearance for the facade(front) pipes.
Romeo, the cat, sits in the pipe tray My cat Romeo preferred the carpet lined pipe trays for nap time.
Rackboard sizing tool Rackboard sizing tool. After pipes are voiced and pitched we put the pipes in the tool to record the size of the hole we will drill in the rackboard. The rackboard supports the pipes.
Joe Brown cuts pipes to desired length Joe Brown cuts the pipes to the correct length for their pitch. These measurements are derived from a spreadsheet on the laptop. The new pipes come long so they all need to be trimmed. The length determines the pitch of the pipe.
Eric Grane at the voicing machine Eric Grane voices pipes in the shop on a small portable organ called the voicing machine. It allows the voicer to have easy access to pipes for adjusting their sound in the voicing process. With a whole rank or more of pipes available to play it allows him to compare the tone quality and volume of all the pipes in the set.
fitting pipes in the rackboards The rackboard mounted just a few inches above the toeboard supports the pipes. The holes vary according to the size of the pipe. When it comes to putting the pipes in the organ you have to use a combination of filing(for holes that are too small with a wood file) and felting(for holes that are too large).
fitting pipes Fitting the pipes of the new mixture