Restoration of a Very Early French Harmonium: Wadding!

2 ply rug yarn. 900 yards!

Making wadding is one of the aspects of harmonium restoration that scares off many people. I'm dense enough to try it because nobody told me I couldn't do it. I started with a 900 yard cone of rug yarn (80% wool/20% nylon), used for weaving rugs. Add some very soft lavender colored split suede leather and mercerized cotton thread and I was good to go.

 

The purpose of wadding is to form a gasket that seals the windchest. The upper part has the reeds and action, and the lower part the reservoir. This enables the instrument to keep the air in the system so it can be played. The upper chest with the reeds is hinged in the front and is lowered on to the valve board. There is a gap of about 3/8” that the wadding fills. There are also partitions between each set of reeds that have wadding seals as well. 

The

Cotton thread for sewing

Cutting the strips of leather evenly and carefully is important so you don't get any irregularities in the finished product, and so that all edges meet nicely.

 

I made a rack for sewing the wadding in 4' lengths, more than the width of the organ side to side. I knew I'd probably have some left over but that's better than not having enough. 

Cross section

The first step is to wind the yarn between the two dowels, stretching it as you go. I started off doing 50 strands but decided that wasn't enough so I jacked it up to 80. That's where most of the 900 yards of yarn went. The reason for stretching is so the yarn will tighten up when the finished wadding comes off the rack and it will expand some to fill the leather tube.

The sewing rack with yarn stretched.

After stretching the yarn I started sewing, making sure the edges meet squarely. It took about 1.5 hours to sew a 4 ft length. I made eight and definitely had some left over.

36 ft of wadding!

After the sewing was done I glued the wadding, seam down, over the location of the original wadding and used duct tape in a few places to hold it still while the glue dried.

 

I didn't feel that the 20% nylon content would compromise the wool at all, and it didn't. Others have used a similar blend with good results. The most important thing with wadding, with this being my only experience in making it, is don't rush and don't be nervous. The world won't come crashing in around your ears if it doesn't work the first time. Be deliberate and use good materials and you'll be fine.