Introduction

Late last summer (2012), I was watching one of those Huell Howser shows on PBS, and Huell briefly talked to a guy who had built his own band organ - One of those organs like you'd find at a merry-go-round or circus. I was somewhat surprised that someone could build one of these in their garage at home. It sounded as improbable as someone saying they had built their own jukebox or piano, so I started researching it online and soon discovered that there were many homemade band organs, calliopes, crank organs and such - as well as a great deal of information and resources for building mechanical musical instruments.

I soon became interested in the prospects of building my own band organ. While browsing the pages of the Carousels.com site, I found a series of articles entitled "Building a Wurlitzer 105" and eventually located a site that offered, for a mere $75, a complete set of construction plans for building a replica of the Wurlitzer Model 105 band organ.  While this idea intrigued me, I soon came down to earth a little and wondered - given my limited inventory of woodworking tools and available space - if maybe I shouldn't start off with something a little less ambitious for my first venture.

I spent another month or so considering other prospects, doing a lot of reading on the pages of Mechanical Music Digest, and becoming especially interested in the idea of building a small crank organ for my first construction attempt. This soon led me to the "John Smith Busker Organ", and after a week or so of mulling it over, I decided I was ready to order the plans and get started. I contacted John Smith in England and ordered a set of plans (somewhere around $63) for his Busker organ, which is a relatively small, lightweight crank organ capable of playing paper music rolls in a range of 20 notes.

The plans are by no means exhaustive, and as I like to have all the materials before I plunge in to something, it took me a while to gather up all of the required materials. There is no list of required materials, so I repeatedly combed through the plans and tried to find everything I would need. (I didn't want to lose momentum on the project by getting stuck waiting on a critical part to be delivered.)

Having received the plans in mid-October, I had most of the necessary materials by the time Christmas vacation arrived. With these items on hand and with my inventory of tools (bandsaw, radial arm saw, belt sander, scroll saw, drill press and various hand and small power tools), I felt anxious to finally get started, so I began.

Just for reference, here are some photos and a parts / supplies list of the materials I've been acquiring, with only a couple of things still needed:

Busker Organ Parts List

(Item Descriptions with Purpose, Mfg./Part #, Vendor and Cost.)

• 1 ITEM: "Closed Cell Foam Tape Weatherstrip 3/16""x3/8""x17'" PURPOSE: Pressure box and reservoir gaskets MFG./PART#: Columbia Aluminum Products #4002 VENDOR: "HD Supply, No. Hollywood CA" QTY: 1 COST: $2.42 
• 2 ITEM: Wood Glue 16 fl. Oz. PURPOSE: Fastening MFG./PART#: Titebond VENDOR: "Home Depot, Alhambra, CA" QTY: 1 COST: $3.42 
• 3 ITEM: Shellac 1qt. Can PURPOSE: Sealing MFG./PART#: Bullseye/Zinsser VENDOR: "Home Depot, Alhambra, CA" QTY: 1 qt. COST: $13.78 
• 4 ITEM: Cardboard Tube (Love My Carpet pkg.) 66mm diameter. PURPOSE: Take up spool core MFG./PART#: Love My Carpet VENDOR: "Dollar Tree, Alhambra, CA" QTY: 1 COST: $1.00 
• 5 ITEM: 20-Note Organ Test & Tuning Roll + Spool PURPOSE: Testing/tuning MFG./PART#: Melvyn Wright VENDOR: http://www.melright.com QTY: $16.08 (1 roll) + $9.70 (1 spool) COST: $25.78 
• 6 ITEM: Book - Getting Started on the John Smith Busker Organ PURPOSE: Instructions MFG./PART#: Melvyn Wright VENDOR: http://www.melright.com QTY: 1 COST: $14.38 
• 7 ITEM: "John Smith 20-note Busker Organ Plans, test roll & DVD package" PURPOSE: Instructions MFG./PART#: John Smith VENDOR: http://www.johnsmithbusker.co.uk QTY: 1 COST: $63.00 
• 8 ITEM: "1/4""-28 Hex Nuts" PURPOSE: Rod to bellows fastening/adjusting MFG./PART#: Crown Bolt VENDOR: "Home Depot, Alhambra, CA" QTY: 6 @ $0.06 COST: $0.36 
• 9 ITEM: "Steel Ball Joint Rod End, 1/4""-28 Rh Female Shank,1/4""ball Id,11/16""l Thrd" PURPOSE: Crank rod ends MFG./PART#: 60645K321 VENDOR: "McMaster-Carr QTY: 2 @ $3.11 ea. COST: $6.22 
• 10 ITEM: 1/8 in. OD 12 in. Length Solid Brass Rod PURPOSE: Roll paper hold down MFG./PART#: K+S Precision Metals #164 VENDOR: "Industrial Metal Supply, Sun Valley, CA" QTY: 2 @ $1.30 ea. COST: $2.60 
• 11 ITEM: 5/16 in. OD 12 in. Length Round Brass Tube PURPOSE: Trackerbar & Lg. Pipe nipples MFG./PART#: K+S Precision Metals #133 VENDOR: "Industrial Metal Supply, Sun Valley, CA" QTY: 1 COST: $2.25 
• 12 ITEM: 1/4 in. OD 36 in. Length Round Brass Tube PURPOSE: Trackerbar & Sm. Pipe nipples MFG./PART#: K+S Precision Metals #1149 VENDOR: "Industrial Metal Supply, Sun Valley, CA" QTY: 2 @ 4.75 ea. COST: $9.50 
• 13 ITEM: "Plain Steel Threaded Rod 1/4""-28 3' length" PURPOSE: Crank to bellows rods MFG./PART#: 98838A029 VENDOR: "McMaster-Carr QTY: 1 COST: $1.84 
• 14 ITEM: "Hardwood dowel 3/16"" x 48""" PURPOSE: Pipe stopper stems MFG./PART#: ? VENDOR: "Home Depot, Alhambra, CA" QTY: 2 @ $0.65 ea. COST: $1.30 
• 15 ITEM: "1/4"" aluminum rod" PURPOSE: "Crankshafts, spool shaft, idler wheel shaft" MFG./PART#: IMS VENDOR: "Industrial Metal Supply, Sun Valley, CA" QTY: 2 @ $1.30 ea. COST: $2.60 
• 16 ITEM: "Round Head Brass Slotted Wood Screws #6x 5/8"" 6pcs./pkg." PURPOSE: Misc. fastening MFG./PART#: Crown Bolt #24301 VENDOR: "Home Depot, Alhambra, CA" QTY: 4 @ $1.18 ea. COST: $4.72 
• 17 ITEM: T-Nuts #10-32 4pcs./pkg. PURPOSE: Mounting pipes (with #23) MFG./PART#: Crown Bolt #18881 VENDOR: "Home Depot, Alhambra, CA" QTY: 5 @ $1.18 ea. COST: $5.90 
• 18 ITEM: "1/2"" x 1/4"" aluminum bar scrap" PURPOSE: Crank arms MFG./PART#: IMS VENDOR: "Industrial Metal Supply, Sun Valley, CA" QTY: 2 @ $0.40 ea. COST: $0.80 
• 19 ITEM: "18-8 Stainless Steel Slotted Spring Pin, 3/32"" Diameter, 5/16"" Length. 100 pcs./pkg." PURPOSE: Crank arm fastening MFG./PART#: 92373A140 VENDOR: "McMaster-Carr QTY: 1 pkg. COST: $2.96 
• 20 ITEM: "Nylon Bearing, Flanged, For 1/4"" Shaft Dia, 3/8"" Od, 5/16"" Length. 5 pcs./pkg." PURPOSE: Crankshaft mounting MFG./PART#: 6389K231 VENDOR: "McMaster-Carr QTY: 1 pkg. COST: $2.45 
• 21 ITEM: Thick Cardboard for Bellows Reinforcement PURPOSE: "Bellows, reservoir" MFG./PART#: Recycled from Sun Laundry Detergent inner box walls VENDOR: QTY: N/A COST: $0.00 
• 22 ITEM: Natural Chamois 3 sq. ft. PURPOSE: "Pipe stoppers, bellows valves" MFG./PART#: Tanner's Select VENDOR: "O'Reilly Auto Parts, Alhambra, CA" QTY: 1 COST: $12.99 
• 23 ITEM: "Round Head Brass Machine Screws #10-32x 1/2"" 4pcs./pkg." PURPOSE: Mounting pipes (with #17) MFG./PART#: Crown Bolt #29531 VENDOR: "Home Depot, Alhambra, CA" QTY: 5 @ $1.18 ea. COST: $5.90 
• 24 ITEM: "Steel Ball Bearing, Flanged Open For 1/4"" Shaft Dia, 11/16"" Od, 5/16""w" PURPOSE: Crankshaft mounting MFG./PART#: 6383K213 VENDOR: "McMaster-Carr QTY: 3 @ $3.02 ea. COST: $9.06 
• 25 ITEM: "Black-oxide Steel Set Screw Shaft Collar, 1/4"" Bore, 1/2"" Outside Diameter, 9/32"" Width" PURPOSE: Crankshaft mounting MFG./PART#: 9414T6 VENDOR: "McMaster-Carr QTY: 6 @ $0.61 ea. COST: $3.66 
• 26 ITEM: "Molded Nylon 20 Deg Pressure Angle Miter Gear, 24 Pitch, 30 Teeth, 1.25"" Pitch Dia, 1/4"" Bore" PURPOSE: Crank handle side mount config. MFG./PART#: 7297K16 VENDOR: "McMaster-Carr QTY: 2 @ $3.17 ea. COST: $6.34 
• 27 ITEM: "Nylon Flange-mounted Sleeve Bearing, For 1/4"" Shaft Diameter" PURPOSE: Crankshaft mounting MFG./PART#: 2827N3 VENDOR: "McMaster-Carr QTY: 2 @ $3.32 ea. COST: $6.64 
• 28 ITEM: "Black Posterboard/cardboard 22""x28""" PURPOSE: Covering take up spool/pipe mouth card spacer MFG./PART#: Pacon Corp. VENDOR: "Dollar Tree, Alhambra, CA" QTY: 1 COST: $0.69 
• 29 ITEM: "Westcott 15"" Stainless Steel Office Ruler with Non Slip Cork Base" PURPOSE: General MFG./PART#: Wescott VENDOR: "Staples Office Supply, Alhambra, CA" QTY: 1 COST: $4.99 

• 30 ITEM: "1/4""birch plywood sheet 2'x4'" PURPOSE: "Pressure box, bellows, sides" MFG./PART#: ? VENDOR: "Home Depot, Alhambra, CA" QTY: 1 COST: $8.37 
• 31 ITEM: Sandpaper 220 grit 20 pcs./pkg. PURPOSE: Wood smoothing MFG./PART#: 3-M Pro-Grade VENDOR: "Home Depot, Alhambra, CA" QTY: 1 COST: $14.97 
• 32 ITEM: " 1/8"" x 4"" x 36"" basswood sheets" PURPOSE: Smaller pipes MFG./PART#: National Balsa VENDOR: http://www.nationalbalsa.com QTY: 6 @ $2.19 ea. COST: $13.14 
• 33 ITEM: "1/8"" X 3"" X 24"" Cherry wood" PURPOSE: Pipe lips MFG./PART#: National Balsa VENDOR: http://www.nationalbalsa.com QTY: 1 COST: $5.80 
• 34 ITEM: Hoover Agitator Belt for Lightweight Uprights Part # 046550AG PURPOSE: "Idler wheel ""tire""" MFG./PART#: Hoover VENDOR: Pandora's OEM Appliance partshttp://www.pandorasoem.com/ QTY: 1 COST: $3.44 
• 35 ITEM: Blackout fabric - white/ecru PURPOSE: "Bellows and reservoir cloth, hinges" MFG./PART#: Roc-Lon # 1144575 VENDOR: "Joann Fabrics, No.Hollywood, CA" QTY: 1 sq. yd COST: $3.49 
• 36 ITEM: "No. 8 Rubber Tubing 1/4""" PURPOSE: Trackerbar to pipes tubing MFG./PART#: ? No. 8 VENDOR: http://www.player-care.com QTY: 12 feet COST: $7.80 
• 37 ITEM: 22 piece assorted spring clamp set PURPOSE: Clamping MFG./PART#: HDX VENDOR: "Home Depot, Alhambra, CA" QTY: 1 COST: $5.88 
• 38 ITEM: "3/16"" x 4"" x 36"" basswood sheet" PURPOSE: Bass pipes MFG./PART#: National Balsa VENDOR: http://www.nationalbalsa.com QTY: 3 @ $2.54 ea. COST: $7.62 
• 39 ITEM: RH Brass Support Hinge PURPOSE: Pressure box lid stay MFG./PART#: Schlage #C9210F3 RH VENDOR: "Home Depot, Alhambra, CA" QTY: 1 COST: $2.27 
• 40 ITEM: Screw feed tube cutter PURPOSE: Trackerbar/ pipe nipple cutting MFG./PART#: Brasscraft #T004 VENDOR: "Home Depot, Alhambra, CA" QTY: 1 COST: $14.97 
• 41 ITEM: Artist asst. ponyhair brushes 5pcs./pkg. PURPOSE: Glue/Shellac application MFG./PART#: LeJour/Linzer VENDOR: "Home Depot, Alhambra, CA" QTY: 1 COST: $3.37 
• 42 ITEM: 6 piece precision file set PURPOSE: Trackerbar hole shaping MFG./PART#: General Tools VENDOR: "Home Depot, Alhambra, CA" QTY: 1 COST: $9.96 
• 43 ITEM: "Pocket caliper4""/100mm" PURPOSE: Measuring MFG./PART#: Empire VENDOR: "Home Depot, Alhambra, CA" QTY: 1 COST: $7.97 
• 44 ITEM: "No. 19 Rubber Tubing 3/4""" PURPOSE: Reservoir to pressure box tubing MFG./PART#: ? No. 19 VENDOR: http://www.player-care.com QTY: 1 foot COST: $3.75 
• 45 ITEM: "No.10 Rubber Tubing 5/16""" PURPOSE: Trackerbar to bass pipes tubing MFG./PART#: ? No. 10 VENDOR: http://www.player-care.com QTY: 3 feet COST: $3.00 

• 46 ITEM: Thread Locker PURPOSE: Crankshaft MFG./PART#: Loctite 271 Red 6ml VENDOR: ebay QTY: 1 COST: $6.95 
• 47 ITEM: 3/32" Pin Punch PURPOSE: Inserting roll pins in crankshaft MFG./PART#: DascoPro 581-0 VENDOR: "Orchard Supply Hardware, So. Pasadena, CA" QTY: 1 COST: $3.99 
• 48 ITEM: 1 5/16" x 2 1/4" Brass Hinges PURPOSE: Pressure Box Lid MFG./PART#: National Hardware V1814 VENDOR: "Orchard Supply Hardware, So. Pasadena, CA" QTY: 1 pair COST: $3.19 
• 49 ITEM: 3/4" x 12" copper pipe PURPOSE: Pressure box & Reservoir fittings MFG./PART#: ? VENDOR: "Orchard Supply Hardware, So. Pasadena, CA" QTY: 1 COST: $3.18 
• 50 ITEM: 1/4" x 10' clear vinyl tubing PURPOSE: pressure water gauge MFG./PART#: LDR Hose VENDOR: "Orchard Supply Hardware, So. Pasadena, CA" QTY: 1 COST: $3.19 
• 51 ITEM: Assorted Rubber Bands PURPOSE: clamping MFG./PART#: ? VENDOR: "Big Lots, Alhambra, CA" QTY: 1 COST: $0.99 
• 52 ITEM: Music Wire Torsion Spring PURPOSE: Reservoir spring MFG./PART#: 9271K113 VENDOR: "McMaster-Carr QTY: 1 COST: $4.00 
• 53 ITEM: Wooden Beads 12/pkg. PURPOSE: Stopper tips MFG./PART#: ? VENDOR: Ebay QTY: 2 COST: $1.99
• 54 ITEM: 2'x4' 1/8" MDF PURPOSE: Spool ends, misc. MFG./PART#: ? VENDOR: "Home Depot, Alhambra, CA" QTY: 1 foot COST: $3.97 

Total so far… $364.80