Introduction: Crank-Powered, Music Roll Organ
Third Prize in the
Design Now: In Motion Contest
This Instuctable will show you how to 3D print a self-playing organ! This Organ has a playable keyboard and a music cob in the back where songs can be customized by sticking pegs in it! The actual sound is made from a pair of chromatic harmonica's reeds.
This was made in Fusion 360 and was my first project! I found Fusion 360 very easy to use and I was able to learn it enough to design this after only watching about 5 or 10 minutes of tutorials. I've had slight 3D modeling experience before using Fusion 360, but not anything on a scale like this. I've also included the project file in case you want to make changes!
This is entered in the IN MOTION CONTEST and your vote would be very much apprecia
This is not fully functional at the moment, so I would not recommend printing it quite yet.
Step 1: Stuff Needed
All that you will need to make this is:
1. A 3D Printer
2. This Harmonica:https://www.aliexpress.com/item/qimei-10-hole-40-t...
3. Roughly 50 #6-32 Round Head Machine Screws
4. 24 Rubber Bands
5. 3 paper clips
6. 22 8d Nails
7. Plasti-Dip Spray
8.Blue RTV Silicone Gasket Maker
9. 10' of 1/4" OD Plastic Tubing
10. 18" of 5/8" OD Plastic Tubing
11. Electrical Tape
Step 2: Printing
There are many parts that need to be printed. Only one copy needs to be printed of each of these except for the Key Sticks, Hinge Lids, & Peg. You need 22 of the sticks and lids and however many pegs you need to make your songs! Once they are all printed, you can start to put it together!
Step 3: Base Assembly
The 3 base parts are are held together by 4 screws as shown in pictures 1 & 2. The Gear box and Shaft Support attach to the back with six screws.
Step 4: Gear Box and Shaft Release Assembly
The Mid Gear had and its Mid Gear Peg are held together with a paper clip and then inserted into the Gear Box. Then you add the Big Gear and Small Gear and then hold them on there by screwing on the Gear Wall.
Next you attach the Crank Handle to the Crank Body and attach both of those to the Small Gear using a paper clip.
As for the Cob Release Spring, it needs to be put into the Shaft Support with 2 rubber bands as it is shown in pictures 8 & 9.
Step 5: Preparing and Putting in the Keys
This is really a key step. I first put electrical tap around the back ends of them and then hot glued a foam strip under the front end of them. This will help cut down on unwanted noise.
After that, I cut the tops of of 22 - 8d screws and hot glued them into the row of holes in the center of the Base. Once the glue dries, you can trim of any excess globs and then stick the keys onto the nails. They should pivot freely.
Step 6: Wind Chest Prep
Now it is timeprepare the Wind Chest! You need to take the Wind Chest, Wind Chest Lid Base, and Wind Chest Lid Top and apply a layer of Blue RTV. You should finger-tighten the screws and let it set for an hour.
After that hour, you can attach the whole Wind Chest Assembly to Lid One and Lid Two. These screws should be tight, but not too tight. Excess blue gloop can be scraped off.
You can set this aside.
Step 7: Pipe, Caps, and Rubber Bands
Now we are making progress! The first thing to do here is to hot glue little squares of foam onto the bottom sides of the HingeLids. Once dry, You can trim of excess foam using some sharp object. (A knife could work.)
The Hinge Lids go on the top of Pipes One and Pipes Two and a paper clip is unbent and stuck through the holes to act as a hinge peg.
Rubber bands are now stretched from the Hinge Lids to the hooks on the pipes.
Now its time to screw the sets of pipes to the Lid/Wind Chest assembly that you set aside earlier.
The screw should be trimmed or else they will get in the way of the Keys. (QUICK TIP: You should have the bolt on the screw before you cut, that way once you make your cut, you can unscrew said bolt and doing so will help re-cut any threads that got damaged in the process.)
Don't set this aside.
Step 8: Putting the Lid on It
The Lid/Wind Chest/Pipes assembly can be put on the Body/Key/Gear Box/Shaft Support assembly. You can screw this on and there are 6-sided (or hexagonal) holes on underside of the Body/Key/Gear Box/Shaft Support assembly the to put your 6-sided (or hexagonal) bolts in!
Step 9: Stick Time
The 22 Key Sticks that you printed should now be inserted in the row of holes on the back of the Pipe assembly.
Now when you push a Key down, it should push up the Key Stick which in turn will push up the Hinge Lid!
Step 10: Reed All About It
Now we are getting to the music!
First you need to take the 4 Chambers, mask them with masking tape, and give them about 6 or 7 coats of Plasti-Dip Spray to help create a gasket for the reeds.
Next you need to take apart that harmonica and put the top reeds in the Top Chambers (Front and Back)and put the bottom reeds in the Bottom Chambers (Front and Back). The little screw holes on the reeds should be taped up to keep air from flowing through them.
Once you screw the Chambers together, you need to cut up 22 little pieces of 1/4" OD Hose each around 1/2" in length. These go in the bottom of the Chambers and then the Chambers should should stick onto the top of the Wind Chest!
Step 11: Hoses
It is time to run hoses from the top of the Chambers to the Pipes. We are only using the green connectors (See Picture 1) the red ones shouldn't be needed. (They were put there as vent in case there was too much air pressure in the reeds, but you can ignore them for now.) Just match the numbers and be careful not to break any connectors when attaching the hose.
The breathing tube can be attached to the big connector on the Wind Chest. I used electrical tape and about 1 1/2' of 5/8" OD Hosing.
Step 12: The Music Cob: the Final Step
Okay, now just take Cob One and Cob Two, screw 'em together, and that does it!
You can now take the Pegs and arrange them in any fashion on the Cob, put the cob on the organ, and start spinning! (Don't forget to breathe into the big tube.)
Step 13: Final Thoughts
Congratulations! You now have your own unique instrument that can play manually or automatically.
I hope to have a video up too at some point!
If you like this please give me a vote in the IN MOTION CONTEST!
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