This article was taken from the November 2014 issue of WIRED magazine. Be the first to read WIRED's articles in print before they're posted online, and get your hands on loads of additional content by subscribing online.
You would generally find a pipe organ in a church, or at least a purpose-built structure to house it. However, if you can settle for a smaller version played by hand, a substitute can easily be made out of PVC pipe and wood. This particular instrument, inspired by some of the devices the Blue Man Group play, uses eight different-length tubes to play eight notes from a low G to a higher G.
What You'll Need
24m of 50mm (NPS 2) PVC pipe, and 8x 50mm elbows, 7m of 50 x 150mm lumber and 4m of 50 x 100mm lumber; three 100mm carriage bolts (with nuts and washers); wood screws 60-75mm long. A mitre saw and drill with a 60mm hole saw are the only tools needed.
Cut the Wood
Cut the 50 x 150mm wood into four, 900mm each. Cut the 50 x 100mm into two sections, 825mm long. This should be the length of the 900mm 50 x 150mm boards minus twice their thickness.
In one 50 x 150mm piece, cut eight holes for the PVC pipe, spaced 85mm apart.
Cut the PVC Pipes
Cut eight pieces of PVC pipe 900mm long for the vertical part of the PVC organ. Eight more pieces will need to be about: (low) G 2,350mm, A 2,000mm, B flat 1,790mm, C 1,545mm, D 1,232 mm, E flat 1,105mm, F 890mm, (high) G 625mm. Leave 5cm extra to fine tune.
Assemble the Frame
Join the four 50 x 150mms with wood screws, attaching the verticals between the horizontals. Place one of the 50 x 100mms even with the front of the instrument (the 100mm side vertical) about 200mm from the top cut-out.
Attach with screws between the 50 x 100mm.
Assemble the Top PVC
Insert the 900mm PVC pieces from the top and attach the elbows below. Drill three 12mm holes in the 50 x 100mm, clearing the PVC. Put two holes on either end after the outside pipe, one in the middle. Drill the same holes in the other 50 x 100mm. Attach using bolts.
Tune and Play
This instrument is meant to be tuned to a G minor scale with an additional high G. Find a test tone for each of the notes and cut the pipe slightly until you get each note. Even a few millimetres can make a difference, so when in doubt, be conservative with your cutting.