emblem MIDI Pedalboard
Russian

Manufacturing

Boards

The whole pedalboard is made of pine. I made it from boards 20x123x3000mm and 20x148x3000mm, fortunately, it was already planed. I used 148mm width boards for the case and 123mm width boards for the keys.

Fretsaw Take a fretsaw and begin to saw.

Case

Case base Now we made a case. Place a base on a floor and attach a center board by the aluminium corners.

Case sides Attach the sides.

Top cover Place a top cover.

Front arc board marking After that, we mark a front arc board. To do it, print a draw on the several pages and copy it to the board by a carbon paper. Besides cuttings, we mark positions for the holes to place guide tubes.

Front ark board After that we made two holes at the opposite corners of every future cuttings to place a fretsaw. ...So, saw. Here is a result.

Our teilless cat Our cat. Tailless.

Rear arc board making - I Rear arc board making - II Now, let's made a rear arc board. To do it, we attach two boards via screws and saw it through a once more template

DON'T THROW OUT THE REST PART!!! It will be usefull.

Keys-I


Washing machine sides Metal plates for keys After that, let's made key's fasteners. There are different ways to attach keys. I used metal plates. Shortly before beginning of pedal construction, we bought a new washing machine, and I had a parts of old one – such nice metal sides. I had cut it and made a two holes for screws 3mm.

Plates attached Conductor Now, we attach these plates to keys. To do it faster, I made a conductor.

Keys in a case Here is it looks in a case;
There is a question – where are the sharp's top pieces? Nowhere, for a while. We will install it later, because it is easier to maniplate with the keys without top pieces.

Tracks

To force the keys move straight up-down, we need a tracks. Two modes of it's placement exist: at the center of the keys or around it. I have choosen the second one, because it is dangerous to make a section in a 20mm board.

Track tubes So, take a 10mm aluminium tube and cut it on 40 pieces by 110mm. In every one we made two holes at 7.5mm from tube sides. After that, we attach tubes to the front arc board in previously marked points.

Keys in the front arc board Now, we install a front board with the tracks to the case and put the keys. Let's made a key markings. We need to mark three lines: keys cuttint, white key sections and sharp pieces places. The first two lines we made by a guideline, the third – by means of pencil and tape measure.

Springs

And now – the most complex thing – springs block. I hadn't classical V-shape springs, but I had a spiral ones, and very strond at that. So, I decided to make once more arc board under the keys, on which the springs will be installed.

Springs arc board As before, we mark and cut an arc board. Note, than now an arc radius is 20mm less then we need. It allows us to put keys on this board and make a marks. I made this board from the pine, but it is better to use a plywood (18mm thickness or two by 10mm, connected by screws).

Spring arc board in the case Keys on the arc Attach an arc to the case and put the even keys. Mark it's positions.

Spring arc board marked Now, we put the rest keys and mark it's position. Here is a result.

Spring hole drillling After that, we drill holes for tubes. To track a drill along the lines marked, I attached a knittng needle to the drill. ...The cat again.

Screw cutted Screw top in the spring arc board We made the holes in then board, let's make holes in the keys. It is unposiible to calculate it's positions beforehand, so we need to mark it. For example, in such way: take a screw, cut a one cm of a neck and sharpen it.

Key hole marking - I Key hole marking - II Take a key and put it on it's place and press. We obtained a mark for a hole.

After that cut an arc on 20mm to make a place for the springs.

Spring tube cutting Spring tubes in a case To make tracks for he springs, I used an aliminium tube 8mm. Cut it on 32 pieces 50-60mm length and put into holes.

washers and springs After that put washers and springs.

Keys-II

Key bottom cut At the points marked by a screw, made the cuts 10mm width and 15mm legth.

White key cuts Now, we make the white key cuts to make it's front height 40mm. Install sharp's top pieces and mark it's positions at a side, to make it visible when top pieces are installed.

Sharp piece holes Setsquare for drill Let's drill holes for the screws. To make it along a key, we set up a setsquare and orient the drill by it.

Sharp piece installed Attach the sharp top pieces. To make it parallel to the key base, we fix it between two boards.
After that we turn this construction over and drive two screws.

Key fronts cutting Now we cut the key ends by the marks made previously. Two-three near keys has the same cut angle, so, it's able to cut it at a one trace, matching line ends.

Keys with the sharp pieces in the case After that we cut the sharps by the lines we marked before. Here is a result.

Bench

It would be discourage to make a pedalboard and not to have ability to play it. So, let's put pedal of and make the bench. I decided to make it from a paywood sheet 18mm thickness and 1.5x1.5m size.

Organ bench details Organ bench It is very easy to make a bench – just connect by the screws.

Photointerrupter PCBs

Corner flexing Corners in front of the keys Let's begin from corners. We made it fromm the same washing machine sides that the plates at keys rear. Note, that the corners have different height and long holes at bottom. It will allowo us to change space between interrupters and keys.

Photointerrupter PCB preparation Next, we prepare PCBs. We made the long holes for adjustment. The top side position must be choosen so the corner doesn't touch the photointerrupter contacts.

Screw and set up.

Keys covering

Key, fleece and staples To make the pedalboard knockless, let's cover the keys front by a fleece. To fix it, we can use staples, which can be driven in by a hammer or stapler.

Front board fleece Cover the front board inside.

 eys-III

Key rears It's a time to fix the keys finally. We drill 3mm holes at the plates and put the keys at it's places.

Keys screwed Screw it.

Electronics

Photointerrupter shutters Photointerrupters need shutters. It can be made from anything but not transparent. I used coffee contaner. Cut it at squares 10x20mm, flex to corner and screw to key's butt. Vertical position is to be choosen to match the shutter middle with an optical axis of photointerrupter, when the key is not held and the PCB is in a middle position. It will allow us to adjust response moment from the earliest to the latest.

Photointerrupters installed Cut the shutters to made it's ends at a one line.

Photointerrupters installed - II Set up PCBs and wire it.

New springs NEW

Key prototype with a plate spring To obtain necessary bend angle, we have made the prototype. The bolt allows to change the force.

Bolts, placed besides the tubes Now slightly ream the tube holes and place the bolts there.

The keys mounted. Bottom view Mount the keys at it's place, beforehand slightly unscrew the bolts.

The keys mounted. Top view Here is the result

Crescendo pedal

I decided to play some romantics. For this, the organ must have a expression pedal. I looked some real organ pedal photos and made this:
Crescendo pedal. Behind view Crescendo pedal. Left view The ratchet latch was made by my dad from the plexiglass (by hands!). The gear was taken from an old printer. The resistor is 10k, the jack – 6mm Stereo.

Crescendo pedal. Temporary installed I temporary fixed the pedal by screw-clamps. I'll made something mo respectable later.

Result

My organ. Manuals My organ So, it's how does my organ seems now.

New springs. Again...NEW


Finaly I decided to make and install V-shape springs. It is standard for pedalboards. I searched Internet and found I need 2.5mm musical wire. I could not found it in my city, so I ordered it by Internet.

Short bar of the coiling tool Long bar of the coiling tool It's hard to coil a spring wire, so we need a special tool. Fortunately, Raphi Giangiulio found a solution. The only disadventage is a high fixing bolt. When rotating a tool it will rest to the wire. It will be need to slide bars apart. It is inconvient. Possible solution is to use shorter bar and two screws. This bar also have a riffle allowing even closer bar sliding.

Wire flexed in a vice Spring draft The spring need a bent end to fix it in a coiling tool. This can be done by hands in a vice.

Coiling tool with a fixed spring Springs finished Now we can coil a spring. Place a bent end between the screws, put a long bar's tube to the hole, and fix a spring's long end with a bolt. Turn the long bar about 1.6 turns. We have a spring!

New felt After new springs installed, keys will strike on a front board, so we need a new 1cm thick felt. It can be simply glued.

Additional spring board Now let's install an additional plywood board. It made the whole construction more strong. It also make a fixed part of the spring longer.

Felt between old springs and bolts Old springs and bolts can be used for key force adjustment. But now these springs are loaded much less. If you release a key too sharply, the back part will jump and you hear BAMM. Felt is the solution here too.

Tube wrench Bolts are very close to each other, so it is inconvient to use an open-end wrench. So we need a line (or tube, or flare-nut) wrench. The slit allows to throw a wrench through a bolt's body. I have not sound such wrench in a shop, so the slit was made by aa angle grinder.

Spring force adjustment Now let's solve a poser. How can we measure a key force on a vertical standing pedalboard? We also need a free hands for wrench manipulations. ...Bingo! We made a wire hook and tie it to the key and to the scales. The scales are attached to the wooden bar, and this bar — to the instrument box. We move the box to achieve semi-pressed key position and turn a bolt to get a force equal to 1.5kg. It is important to hook a key in a right place. The sharp keys should be hooked on a middle of the sharp piece, and the white keys over a line through sharp's butt-end.

Foot controller stand Also I made a new foot controller stand.

Cat The tailless. Again...

15.02.14
Even new springs

20.05.10
New springs photos

20.05.10
Crescendo pedal photos

18.05.10
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