- Details
- Last Updated: 19 May 2016 19 May 2016
Popper Salon Orchestra No.1 with Harmonium
Originally built from 1912 into the 1920's. This was one of the most popular Orchestrion model Popper made. Instruments consists of Piano, Mandolin, Bass Drum, Snare Drum, Bells, Xylophone, Cymbal, Triangle and Wood Block. Also has a double rank
of pipes ( Violin and Cello). This unit is also equipped with the optional Harmonium. This unit is 9 1/2 foot tall, 6 foot wide and a little over 3 foot deep.
*****THE RESTORATION*****
Player Action
Unfortunately silicone and PVC-E glue was used on the previous work preformed on this instrument which takes extra time to prep the surfaces for the use of the Correct materials. This player uses Pillow/Puffer Pouches. There are 2 issues here.1. The pouches where replaced with leather and where originally made of Zephyr skin. Zephyr Pillow Pouched are much more responsive and air tight.2. Cardboard donuts where used to attach the pouches can leak in time and the cardboard can split (see picture) causing that note not to play among other problems. New donuts are made of packing leather. This pneumatic action is divided into 2 sections for expression. Both section has its own regulated vacuum source operated by the roll. The divider in the vacuum chamber was neglected when last worked on and the vacuum was allowed to pass through disabling the expression capability. See pictures for repairs.
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before before
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Taking everything apart. Taking everything apart.
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Caps glued down with PVC-E glue. A BIG NO NO! Caps glued down with PVC-E glue. A BIG NO NO!
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This is showing how the cardboard donuts can split. This note did not work in this condition. This is showing how the cardboard donuts can split. This note did not work in this condition.
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New Pillow pouches. Aren't they cute! New Pillow pouches. Aren't they cute!
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When installing, if you leave the pusher disks off, you can shine a light in the supply hole to line up the pouch hole perfect. When installing, if you leave the pusher disks off, you can shine a light in the supply hole to line up the pouch hole perfect.
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Complete! Complete!
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All new Pneumatica where made. All new Pneumatica where made.
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All the Pneumatics. All the Pneumatics.
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Valves re-built Valves re-built
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All done! Valve caps use Blotter Paper for gaskets so they can be removed in the future without damaging the surfaces. All done! Valve caps use Blotter Paper for gaskets so they can be removed in the future without damaging the surfaces.
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Back together. All pneumatics are new. The wood used varied in color. Back together. All pneumatics are new. The wood used varied in color.
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Damaged bridge. Damaged bridge.
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Repaired bridge. Repaired bridge.
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Adjusting the valve travel with custom tool. Adjusting the valve travel with custom tool.
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Adjusting the valve travel with a digital gauge. Adjusting the valve travel with a digital gauge.
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COMPLETE! COMPLETE!
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Completed unit with dust covers off. Completed unit with dust covers off.
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Completed unit with all the dust covers installed. Completed unit with all the dust covers installed.
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Pushrods will be installed later. Pushrods will be installed later.
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https://robertsmusicalrestorations.com/index.php/restoration-projects/completed/28-popper-salon#sigProIdc0b92f6d21
Pressure/Vac Pump
The main issue among many with this pump was on the vacuum side. As noted in the pictures, the main vacuum output hole was blocked by the pneumatic inside the control box that turned off and on the vacuum supply. There was only a 1/8” slit allowing the vacuum to pass through. The main hole was widened and a new hole was made that was not obstructed by anything. That should do the trick!
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Before Before
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Glued down with PVC-E glue. A big No No! Glued down with PVC-E glue. A big No No!
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New leather was installed over the old leather. First time I saw this one... New leather was installed over the old leather. First time I saw this one...
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Old flaps. Flap hold where stapled on. A few fell off. Some where so tight that the flap could hardly move. Old flaps. Flap hold where stapled on. A few fell off. Some where so tight that the flap could hardly move.
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New flap springs made. New flap springs made.
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Before and After. The main board was ran through a large drum sander to ensure the surface was totally flat and then sealed. Before and After. The main board was ran through a large drum sander to ensure the surface was totally flat and then sealed.
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This is the vacuum outlet hole. As you can see it was mostly blocked. This is the vacuum outlet hole. As you can see it was mostly blocked.
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New hole was cut. New hole was cut.
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Done Done
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Also decided to widen the original hole. Also decided to widen the original hole.
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Complete Complete
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Viewing from inside the reservoir. Now the original hole has better pass through and the new hole will allow for unrestricted flow. Viewing from inside the reservoir. Now the original hole has better pass through and the new hole will allow for unrestricted flow.
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View from inside the reservoir. View from inside the reservoir.
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COMPLETE!! COMPLETE!!
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Bottom Bottom
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Before and After Before and After
https://robertsmusicalrestorations.com/index.php/restoration-projects/completed/28-popper-salon#sigProIde523b13d9f
Xylophone and Glockenspiel (bells)
A lot of special care is put into the Xylophone and Bells being that they are principal instruments and need to operate and sound the best they can. I have had great success in the past adding a couple of “upgrades” to the xylophone that greatly improves the performance and sound. Throughout the years the mallet shanks start to warp and bend, causing the mallet heads to deaden out on the bars (stopping the tone short). There is the option to heat and bend the shanks back to their original position but in the future they will just warp again. So, to permanently correct this problem while building new Pneumatics, a “limit adjusting screw” was added to each pneumatic and a leather bumper was installed inside the pneumatic so the screw wont wear into the wood. Now the mallet travel can be adjusted to prevent the mallets from bottoming out on the bars giving the xylophone a nice clean tone. Another addition was adding a spring rail similar to the same design as the Bell unit. Some Poppers have limited space and this can’t be performed but in many cases it can. The main problem with the original “hinge springs” is that you can’t achieve equal tension from one pneumatic to another and ultimately affects the repetition and volume. Even though some might argue it’s a small difference, this is one of many reasons why our restorations sound like no others, because nothing gets over looked. Every small regulation will guarantee success at the end!
Additionally, all bars where tuned, Xylophone and Bells. When restoring Orchestrions it always amazes me how off tune the Xylophones and Glockenspiels are. In this case when originally tested, one bar would be 25cents flat and the neighboring bar be 20cents sharp. If you tuned a piano like this it would sound horrible! Tuning bars isn’t a quick process being that each time you grind a bar for tuning heat is generated and the bar must cool back down to room temperature so an accurate reading can be made. It normally takes 3 tunings between rests to get the bars tuned SPOT ON! For some reason the bell bars where painted black. Paint was removed, buffed and plated and tuned.
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Before Before
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After After
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Added screw adjusters. Added screw adjusters.
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New Pneumatics (Hinges ready to be trimmed) New Pneumatics (Hinges ready to be trimmed)
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Adjuster bumper. Adjuster bumper.
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Completed Pneumatics Completed Pneumatics
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New spring rail. New spring rail.
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Complete Complete
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Backside Backside
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Before and After. Notice that the newer wire was replaced with cotton braided wire like original. Before and After. Notice that the newer wire was replaced with cotton braided wire like original.
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Original hinge springs and the added spring rail. Original hinge springs and the added spring rail.
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Before and After Before and After
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Before and After Before and After
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Before and After Before and After
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Before Before
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After After
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Before and After Before and After
https://robertsmusicalrestorations.com/index.php/restoration-projects/completed/28-popper-salon#sigProId937a58e7cf
Register
Register box when opened for the first time. Seats where sealed with silicone. A sloppy job at that! Will be adding more pictures as completed.
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Register box when opened for the first time. Seats where sealed with silicone. Register box when opened for the first time. Seats where sealed with silicone.
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Everything will be cleaned and then re-done the correct way! Everything will be cleaned and then re-done the correct way!
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New puffer pouches New puffer pouches
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Nickel plated the brass seats to eliminate future corrosion. Nickel plated the brass seats to eliminate future corrosion.
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seats installed. Using no GOOP :-) seats installed. Using no GOOP :-)
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New valves New valves
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All valves installed All valves installed
https://robertsmusicalrestorations.com/index.php/restoration-projects/completed/28-popper-salon#sigProId2ba9ab6298
Miscellaneous completed items
Pictures will be added to this section throughout restoration.
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Hanging light before and after Hanging light before and after
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Miscellaneous completed pneumatic parts. Miscellaneous completed pneumatic parts.
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Made a Capstan rail to take up the slack in the piano action. Made a Capstan rail to take up the slack in the piano action.
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Rail installed. Now the action can be regulated and wont bind up on the pushrods when the piano is installed in the case. Rail installed. Now the action can be regulated and wont bind up on the pushrods when the piano is installed in the case.
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Painting drum hoops. Not fun :-) Painting drum hoops. Not fun :-)
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https://robertsmusicalrestorations.com/index.php/restoration-projects/completed/28-popper-salon#sigProIdb7028e78fb
*****COMPLETED*****
Note: The "moving Painting will be completed very soon. When installed new pictures will be added. Please check back.
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Completed!! Painting will be added soon! Completed!! Painting will be added soon!
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A look at the interior. A look at the interior.
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Back side Back side
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Pipes Pipes
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Pump Pump
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Harmonium Harmonium
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Register "Pot Valves" Register "Pot Valves"
https://robertsmusicalrestorations.com/index.php/restoration-projects/completed/28-popper-salon#sigProId59623d18f9
Audio and Video **Click play to listen!