QUOTE(Holz Gedeckt @ Jul 6 2009, 11:58 PM)

QUOTE(Swell Box @ Jul 6 2009, 10:09 PM)

I am guessing here, but from my knowledge of boat building....
Organs and boats are two of my main hobbies! I've done some pretty major work in 'fibreglass' with one of my boats, and enjoyed the learning curve

Out of interest, do you think that GRP might possibly be of use in any aspect of organ building? It has gradually replaced wood in most aspects of boat-building over the last 50 years (would that my present boats were without time-consuming brightwork!

). Do you think there's potential for it to be utilised in organ building, SB?
Argghhhg. Plastic organs? What a thought!

Anyhow, the 32' ranks might get blisters.
Seriously though, there is no technical reason why an organ should not be built using composites. After all, plywood and particle boards, both of which are widely used in organ building, are themselves composites. However, there are a number of practical difficulties:
1) In my view, composites would be ideal for some components, such as wind chests and conveyances; but these are nearly always 'one-offs' nowadays, so the tooling costs would be disproportionally high.
2) Composite organ pipes would probably sound very different to woods or metal pipes. Lead alloys are acoustically quite dead, (being both soft and heavy), but a composite pipe would almost certainly introduce a ‘colour’ of its own; which may not be unpleasant, but would be 'different' all the same. (Think of a plastic acoustic guitar, for instance.)
Whilst lead alloys have their drawbacks, they are easily fashioned into the desired shape; which composites are not. This would make individual ‘voicing’ of composite pipes very difficult, unless of course the pipes were designed to accept metal mouths.
Large woods, like Bourdons, would introduce their own problems owing to their box like shape. A conventional single skinned bourdon would need to be quite heavily laid up (and therefore both heavy and expensive) to avoid 'panting', which would add unwanted colour to the sound, and may sound rather ‘flatulent’. That is why boats, and cars, tend to have lots of curves, which provide what we call 'shape stiffness'.
A sandwich construction bourdon (using a balsa or polyurethane foam core, sandwiched between thin layers of GRP) would be lighter and stiffer; but again, the costs involved would be disproportionally high.
3) There is also the question of Health and Safety: Wood is easy and pleasant to fabricate using normal hand or power tools, and does not require special handling. GRP composites, on the other hand, are fabricated using hazardous materials, and once cured are much more difficult to machine. Furthermore, the glass reinforcement in GRP creates irritating dust, and cutting tools have a much shorter lifespan than when cutting wood.
Your comparison with the boatbuilding industry is interesting: Production boat builders switched to GRP composites because the raw materials were much cheaper than timber, and were more readily available. But more to the point, mass fabrication was quicker, cheaper, and more consistent (owing to the use of moulds), and did not require a skilled workforce; which is why so many GRP boats from the 1970’s and early 80’s were so badly laid up! And of course GRP was widely regarded as ‘maintenance free’ in those days, and so we were told would not even attract marine fouling. It’s just a shame nobody told the barnacles!
Organ building, by contrast, is very labour intensive, and usually involves one-off components, so the raw materials account for a much smaller proportion of the manufacturing costs than in boatbuilding.
Regarding the use of bones: as far as I know, the bones from any long-lived creature (elephants, horses and whales come to mind

) can be used to make knife handles, or to face the keys on a piano or organ. I don’t think that the bones of short lived creatures would have the desired mechanical properties, but I may well be wrong on this subject.
SB