Pipe Making Part 1: Casting Metal - Pouring and Preparing

This excerpt is taken from a documentary film on the construction of Martin Pasi's Opus 14, It shows the pouring and preparation of metal for casting an organ pipe. This segment was filmed by Mike Cousino in the Pasi Organ Builders shop in Roy, Washington. Part 1 of 6.

[@Larsky1010]

This appears to be a very hot, very difficult, very dangerous art. Yet you do it with such skill that it almost looks easy. Almost. Fascinating!

[@richirovy]

Thank you for all these videos. They are very interesting and I'm fascinated about organ building

[@martinpasi]

The piece is " Wie schoen leuchtet der Morgenstern" by Johann Ludwig Krebs, a student of Bach. The artist is Craig Cramer of Notre Dame, South Bend, Indiana.

[@falaqdad15]

AAAHHHHHHHHHHH IIITTTTT BURRRNNNNSSS!!!!!!!!!!!!! ; ) Thanks for the videos, they are quite fascinating to me.

[@jamespaulo664]

Adorei este trabalho

[@josuerodrigues8014]

Excelente trabalho

[@MMorbid0000]

Thank you for your reply, Martin Pasi! I will try pouring over a high temp cloth.

[@martinpasi]

Mike Morabito: We use nomex cloth on top of a granite slab. The cloth keeps the bubbles away and keeps the metal on the table. In addition to the cloth we also use a thins nomex felt under the cloth.

[@potocnikhoce]

What is that spray that you put on Al folie?

[@Fluyt4Vt]

@BuickDoc the alloy is lead with tin.

[@BuickDoc]

What is the metal alloy?

[@GOLDVIOLINbowofdeath]

Somewhere I read what the minimum % of tin there must be to get the spotted result. Is it 70 or 80%?

[@mikemorabito5401]

What is the surface you're pouring onto? I build a small sled like yours and tried to pour pewter sheets on a polished granite surface. I got a smooth top surface, but bubbles underneath. I was thinking about trying to pour over a linen sheet to allow gasses to escape from underneath the sheet. Thanks for the great video, it was inspiring!

[@bvsiness]

Which "Wie schön leuchtet" prelude is this? ANy Imslp reference? Thanks in advance!

[@MMorbid0000]

Based on your advice, I've had some success pouring pewter sheets 1.5mm thick. Thank you for the cloth suggestion! How old is the technique you are using? A recent or older invention?

[@HugoFBPalma]

What is the name of the piece being played? And what is the name of its artist? Thanks!

[@martinpasi]

Using cloth is an old trick. Before Nomex people used and I think still use linen. Linen burns up quite fast especially with high lead alloys. Linen has been used for hundreds of years.

[@mohamed-larbiloudiyi5299]

Thank you for the great video!!! Based on it, I build a 5m Table with iron armature and granite (1.2m x 5.5m), as well as a wooden box (with ash). Could you share the caracteristics of the nomex cloth (thickness and composition)? I would like to purchase it? At which temperature are you working? Many thanks

[@BRadfrommalibu74]

What do you do with the metal that runs off the end of the casting table? Can it be remelted?

[@praestant8]

Yes.

[@martinpasi]

silicone spray to get a smother start.

[@arifrahmatindriadha6631]

Its amazing and inspiring. From your video is it possible to make lead sheet with dimension is 10m length x 1m width x 2 mm of thicknes ? Could you please share your email for further discussion ?

[@martinpasi]

Who was your teacher?

[@martinpasi]

The lead has not affected anyone. I don't know of any cases where it did in this context. This is a very hot place when we cast and putting on a lot of clothing would make it impossible to do the job. We are very careful and developed a skill to handle splattering. Yes, I think that is how the Romans did it except they probably cast the lead on a bed of sand.

[@PointyTailofSatan]

As a former chemist, I can tell you that lead IS a serious issue in this case. A simple activated charcoal respirator would easily absorb any lead fumes and.or dust. You should seriously consider it. If you don't believe me, call Casavant Freres. lol

[@guikirsch6602]

The lead.. has it affected anyone's health yet?

[@praestant8]

No.

[@christopherwhitelaw1197]

Bare arms, molten metal. Bad mix.

[@Walletau]

You're poring molted lead with out sleeves, an apron, facemask or goggles...

[@Veggietalesfan32]

If I give you a five, how the hell do you expect to give me change?

[@kenkappler9352]

There is nothing to be learned here. I was expecting something educational. You don't tell us anything about what is going on, and watching you do it is a waste of time. Won't be back.