How We Made “4 resonant, rattling piles of metal”
Back in the spring 2014, the NBJH Wind Ensemble performed John Mackey's piece Foundry. Our students had a blast rehearsing and performing this challenging composition!
One part of the preparation was building "4 resonant, rattling piles of metal", as described in the score and on John Mackey's site:
4 resonant, rattling piles of metal or other rattling metal objects, such as train rails with other metal leaned on top. Must have some resonance.
Since then, this metal piles instrument has been used by more than half a dozen band programs performing Foundry. This is the story of how it was built.
Each performing group is allowed the freedom to interpret this description, designing their own version of the instrument. You can see several photos of different constructions on Mackey's blog post about Foundry.
Using the Texas State University recording and this video from Utley M.S. (Rockwell, TX) as a sonic guideline, we began the adventure of putting together the 4 Metal Piles instrument. Iteration on the design was key to getting the sound we wanted; changes in mounting systems, materials, length, height, etc. were all tried and tested as the instrument was built and refined.
We had several goals when building our instrument:
reliable: the instrument had to stand up to hours of rehearsal and several performances, as well as remaining playable over the years when the piece is performed again (and again)
consistent: the instrument had to produce (relatively) the same sound each time it was played, and have the requisite four distinct pitch "areas" - low, mid-low, mid-high, high.
portable: our band room and performance space are on different floors
reproducible: if any part of the instrument required replacing, an easy solution was the goal; also, we hoped to share our design with the larger band community
We tried different approaches for changing the resonant quality of the instrument. The picture above shows different cut-outs in the base to test their effect on how the metal projected its sound.
Read more about the design and construction below in the Design Notes.
To hear our instrument in context of the full piece, scroll down to listen to The Performance.
Photos, Parts List and Design Notes: 4 Metal Piles Instrument
Below are annotated pictures and the corresponding (downloadable) parts list for our version of the 4 Metal Piles instrument. You can click any of the photos for a larger view.
Annotated Photos
Full view of the "4 metal piles" instrument. Sitting on top are the 2oz ball pein hammers that were essential in getting the correct resonance from the metal bars.
Detailed view of the mounting system for each metal bar. The letters reference the parts list to the right.
Side/top view showing wing nuts, fender washers and metal bars.
Side view showing extra cymbal felts used with the angle irons.
Performer view showing pitch-based layout of the metal bars.
Parts List
[A] 30”x40” MDF base
[B] folding table legs (qty: 4)
[source: Rockler part #22873]
[C] 1” x 3” MDF border; 1 1/4” #8 Buildex Teks lath screws (qty: 5 per side)
[D] 5/16” x 7 1/2” full-thread tap bolts (qty: 8)
[source: McMaster Carr SKU#92865A614]
[E] 5/16” x 1 1/2” fender washer (top and bottom of base) (qty: 16)
[source: Menard's SKU#2329555]
[F] 5/16” nylon-insert nut (qty: 8)
[source: Menard's SKU#2320273]
[G] 5/16” x 1/2” washer (qty: 8)
[source: Menard's SKU#2027743]
[H] 1/2” x 3 9/16” compression spring (qty: 8)
[source: Menard's SKU#2026990]
[I] 5/16” x 1 1/4” fender washer (top and bottom of metal bars) (qty: 16)
[source: Menard's SKU#2011217]
[J] cymbal felts (top and bottom of metal bars) (qty: 20)
[K] 5/16” nylon-insert wing nut (qty: 8)
[source: McMaster Carr SKU#98520A140]
[L] 2 oz ball pein hammer (qty: 2)
[source: Vaughan Mfg. Co.]
[M] 1/8" x 1" weldable steel angle (qty: 1)
[source: Menard's SKU#2279703]
[N] 1/8" x 1 1/2" weldable steel angle (qty: 1)
[source: Menard's SKU#2279729]
[O] 1” weldable steel square tube (qty: 1)
[source: Menard’s SKU#2279800]
[P] 1” plated steel perforated tube (qty: 1)
[source: Menard’s SKU#2278199]
Design Notes
Though referenced repeatedly as “4 metal piles”, our instrument more aptly falls under the “other rattling metal objects” from Mackey’s description. The mounting system, in addition to allowing the metal bars to float, provided the extra rattle indicative of the desired sound. The compression springs [H], fender washers [E] and [G], and the tap bolts [D] all add the rattle quality when the metal bars are struck with the ball pein hammer.
Admittedly, our path to this instrument was not inexpensive. Finding our materials via commercial outlets was the best way to meet our goals; this is obviously not for everyone. It is entirely possible to build a quality instrument for less money with these kinds of modifications, for example:
make a base from any plywood or MDF on hand
eliminate the MDF border and lath screws
eliminate the folding table legs
use mallets or hammers already on hand
choose not to paint the base
use shorter tap bolts (or other bolts) that are less expensive
Of course, you can certainly build your instrument without purchasing any of the materials! The best route for us is what is shared here.
The Performance
When this blog post originally appeared on the Northbrook District 28 Bands website, John Mackey commented.
So. Awesome.
Thank you…
A heartfelt "thank you" to John Mackey for this outstanding composition; it inspired the students and adults involved from preparation to performance.
This project would not have been possible without the generous donation of time and energy from one of the most dedicated band parents around - my father, Jim Scapillato. Along with his friend Rich, Jim spent many hours sourcing materials, building test rigs, and refining the "4 metal piles" instrument in response to feedback.
His patience and creativity were invaluable!
Are you a band director in the greater Chicagoland area? Is your group performing Foundry? We welcome requests to borrow the 4 Metal Piles instrument. Contact me.
Questions? Please feel free to contact me. Clang.