"They were pursuing their rounds, and performing their duties with an ease and facility that promised a speedy termination to their labors, when suddenly they came upon an instrument that, from its external appearance,—solidly rich, yet free from the frippery that was then rather in fashion,—attracted their attention. One of the company opened the case, and carelessly struck a few chords. The others were doing the same with its neighbors, but somehow they ceased to chatter when the other instrument began to speak. One by one the jurors gathered round the strange polyphonist, and, without a word being spoken, every one knew that it was the best piano-forte in the Exhibition. The jurors were true to their duties. It is possible that some of them had predilections in favor of other makers; it is certain that one of them had,—the writer of the present notice. But when the time for the award came, there was no argument, no discussion, no bare presentment of minor claims; nothing, in fact, but a hearty indorsement of the singular merits of the strange instrument."
From that time the Steinways made rapid progress. The tide of California gold was flowing in, and every day some one was getting rich enough to treat his family to a new piano. It was the Messrs. Steinway who chiefly supplied the new demand, without lessening by one instrument a month the business of older houses. Various improvements in the framing and mechanism of the piano have been invented and introduced by them; and, while some members of the family have superintended the manufacture, others have conducted the not less difficult business of selling. To this hour, the father of the family, in the dress of a workman, attends daily at the factory, as vigilant and active as ever, though now past seventy; and his surviving sons are as laboriously engaged in assisting him as they were in the infancy of the establishment.
Besides the Chickerings and the Steinways, there are twenty manufacturers in the United States whose production exceeds one hundred pianos per annum. Messrs. Knabe & Co. of Baltimore, who supply large portions of the South and West, sold about a thousand pianos in the year 1866; W. P. Emerson of Boston, 935; Messrs. Haines Brothers of New York, 830; Messrs. Hallett and Davis of Boston, 462; Ernest Gabler of New York, 312; Messrs. E. C. Lighte & Co. of New York, 286; Messrs. Hazelton and Brothers of New York, 269; Albert Webber of New York, 266; Messrs. Decker Brothers of New York, 256; Messrs. George Steck and Co. of New York, 244; W. I. Bradbury of New York, 244; Messrs. Lindeman and Sons of New York, 223; the New York Piano-forte Company, 139. About one half of all the pianos made in the United States are made in the city of New York.
To visit one of our large manufactories of pianos is a lesson in the noble art of taking pains. Genius itself, says Carlyle, means, first of all, "a transcendent capacity for taking trouble." Everywhere in these vast and interesting establishments we find what we may call the perfection of painstaking.
The construction of an American piano is a continual act of defensive warfare against the future inroads of our climate,—a climate which is polar for a few days in January, tropical for a week or two in July, Nova-Scotian now and then in November, and at all times most trying to the finer woods, leathers, and fabrics. To make a piano is now not so difficult; but to make one that will stand in America,—that is very difficult. In the rear of the Messrs. Steinway's factory there is a yard for seasoning timber, which usually contains an amount of material equal to two hundred and fifty thousand ordinary boards, an inch thick and twelve feet long; and there it remains from four months to five years, according to its nature and magnitude. Most of the timber used in an American piano requires two years' seasoning at least. From this yard it is transferred to the steam-drying house, where it remains subjected to a high temperature for three months. The wood has then lost nearly all the warp there ever was in it, and the temperature may change fifty degrees in twelve hours (as it does sometimes in New York) without seriously affecting a fibre. Besides this, the timber is sawed in such a manner as to neutralize, in some degree, its tendency to warp, or, rather, so as to make it warp the right way. The reader would be surprised to hear the great makers converse on this subject of the warping of timber. They have studied the laws which govern warping; they know why wood warps, how each variety warps, how long a time each kind continues to warp, and how to fit one warp against another, so as to neutralize both. If two or more pieces of wood are to be glued together, it is never done at random; but they are so adjusted that one will tend to warp one way, and another another. Even the thin veneers upon the case act as a restraining force upon the baser wood which they cover, and in some parts of the instrument the veneer is double for the purpose of keeping both in order. An astonishing amount of thought and experiment has been expended upon this matter of warping,—so much, that now not a piece of wood is employed in a piano, the grain of which does not run in the precise direction which experience has shown to be the best.
The forests of the whole earth have been searched for woods adapted to the different parts of the instrument. Dr. Rimbault, in his learned "History of the Piano-forte," published recently in London, gives a catalogue of the various woods, metals, skins, and fabrics used in the construction of a piano, which forcibly illustrates the delicacy of the modern instrument and the infinite care taken in its manufacture. We copy the list, though some of the materials differ from those used by American manufacturers.
| Materials. | Where used. | |
| Woods. | From | |
| Oak | Riga | Framing, various parts. |
| Deal | Norway | Wood-bracing, &c. |
| Fir | Switzerland | Sounding-board. |
| Pine | America | Parts of framing, key-bed or bottom. |
| Mahogany | Honduras | Solid wood of top, and various parts of the framing and the action. |
| Beech | England | Wrest-plank, bridge or sound-board, centre of legs. |
| Beef-wood | Brazils | Tongues in the beam, forming the divisions between the hammers. |
| Birch | Canada | Belly-rail, a part of the framing. |
| Cedar | S. America | Round shanks of hammers. |
| Lime-tree | England | Keys. |
| Pear-tree | —— | Heads of dampers. |
| Sycamore | —— | Hoppers or levers, veneers on wrest-plank. |
| Ebony | Ceylon | Black keys. |
| Spanish Mahogany | Cuba | For decoration. |
| Rosewood | Rio Janeiro | For decoration. |
| Satinwood | East Indies | For decoration. |
| White Holly | England | For decoration. |
| Zebra-wood | Brazils | For decoration. |
| Other fancy woods | —— | For decoration. |
| Materials. | Where used. |
| Woollen Fabrics. | |
| Baize; green, blue, and brown | Upper surface of key-frame, cushions for hammers to fall on, to damp dead part of strings, &c. |
| Cloth, various qualities | For various parts of the action and in other places, to prevent jarring; also for dampers. |
| Felt | External covering for hammers. |
| Leather. | |
| Buffalo | Under-covering of hammers-bass. |
| Saddle | " " tenor and treble. |
| Basil Calf Doeskin Seal Sheepskin Morocco | Various parts of action. |
| Sole | Rings for pedal wires. |
| Metal. | |
| Iron Steel Brass Gun metal | Metallic bracing, and in various small screws, springs, centres, pins, &c., &c., throughout the instrument. |
| Steel wire | Strings. |
| Steel spun wire | Lapped strings. |
| Covered copper wire | " " lowest notes. |
| Various. | |
| Ivory | White keys. |
| Black lead | To smooth the rubbing surfaces of cloth or leather in the action. |
| Glue (of a particular quality made expressly for this trade. | Woodwork throughout. |
| Beeswax, emery paper, glass paper, French polish, oil, putty powder,spirits of wine, &c., &c. | Cleaning and finishing. |
Such are the materials used. The processes to which they are subjected are far more numerous. So numerous are they and so complicated, that the Steinways, who employ five hundred and twelve men, and labor-saving machinery which does the work of five hundred men more, aided by three steam-engines of a hundred and twenty-five, fifty, and twenty-five horse-power, can only produce from forty-five to fifty-five pianos a week. The average number is about fifty,—six grand, four upright, and forty square. The reader has seen, doubtless, a piano with the top taken off; but perhaps it has never occurred to him what a tremendous pull those fifty to sixty strings are keeping up, day and night, from one year's end to another. The shortest and thinnest string of all pulls two hundred and sixty-two pounds,—about as much as we should care to lift; and the entire pull of the strings of a grand piano is sixty pounds less than twenty tons,—a load for twenty cart-horses. The fundamental difficulty in the construction of a piano has always been to support this continuous strain. When we look into a piano we see the "iron frame" so much vaunted in the advertisements, and so splendid with bronze and gilding; but it is not this thin plate of cast-iron that resists the strain of twenty tons. If the wires were to pull upon the iron for one second, it would fly into atoms. The iron plate is screwed to what is called the "bottom" of the piano, which is a mass of timber four inches thick, composed of three layers of plank glued together, and so arranged that the pull of the wires shall be in a line with the grain of the wood. The iron plate itself is subjected to a long course of treatment. The rough casting is brought from the foundery, placed under the drilling-machine, which bores many scores of holes of various sizes with marvellous rapidity. Then it is smoothed and finished with the file; next, it is japanned; after which it is baked in an oven for forty-eight hours. It is then ready for the bronzer and gilder, who covers the greater part of the surface with a light-yellow bronzing, and brightens it here and there with gilding. All this long process is necessary in order to make the plate retain its brilliancy of color.
Upon this solid foundation of timber and iron the delicate instrument is built, and it is enclosed in a case constructed with still greater care. To make so large a box, and one so thin, as the case of a piano stand our summer heats and our furnace heats (still more trying), is a work of extreme difficulty. The seasoned boards are covered with a double veneer, designed to counteract all the tendencies to warp; and the surface is most laboriously polished. It takes three months to varnish and polish the case of a piano. In such a factory as the Steinways' or the Chickerings', there will be always six or seven hundred cases undergoing this expensive process. When the surface of the wood has been made as smooth as sand-paper can make it, the first coat of varnish is applied, and this requires eight days to harden. Then all the varnish is scraped off, except that which has sunk into the pores of the wood. The second coat is then put on; which, after eight days' drying, is also scraped away, until the surface of the veneer is laid bare again. After this four or five coats of varnish are added, at intervals of eight days, and, finally, the last polish is produced by the hand of the workman. The object of all this is not merely to produce a splendid and enduring gloss, but to make the case stand for a hundred years in a room which is heated by a furnace to seventy degrees by day, and in which water will freeze at night. During the war, when good varnish cost as much as the best champagne, the varnish bills of the leading makers were formidable indeed.