Well I bit the bullet today and started the new organ. Got the windchest laid out and worked out the pipes sizes. Cut out 24 pipes and started gluing them and got my local wood worker to run me up some bits that make pipe construction much easier. Once I have something to show I will post a piccy and perhaps even try and put together a short video showing my pipe technique which may help others.
By my reckoning I only have another 132 pipes to go or maybe 148 if I add a third rank of counter melody