DanKnowles - Posted - 12/30/2009:  17:38:41

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Quickstep,
Thank you for your kind words, it's folks like you who keep me coming back to this each day.

Bob Robert - Posted - 12/30/2009:  19:21:00

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Like Quickstep, I thought the idea of an ebony banjo was cool enough in itself, but this is just amazing. I guess it's kind of like knowing that your uncle is going to get a new car, thinking he's going to get a BMW Z3 or something along those lines, then finding out that what he really got was a Ferrari. Way cooler than you even anticipated.

Bob

Reneker - Posted - 12/31/2009:  05:46:16

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Thank you letting us follow your banjo build. To me it is a masterpiece. Good luck and please keep those posts coming!

Bob
Springdale, Arkansas

Old Chorizo - Posted - 12/31/2009:  06:21:09

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Dan, any chance that if I sent you my address, this banjo would come to my door!!???

On a more serious note, that is a really nice looking project you have there. I am excited to see what its going to look like when it is finished.

jbalch - Posted - 12/31/2009:  12:17:05

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For all who are following this thread:

I've had the great fortune of visiting my friend David Emery during the holidays. I've been playing David's original Dan Knowles all-ebony banjo again. The experience has served to remind me of how magnificent this banjo sounds. It is simply amazing. The tone and power is unsurpassed (no hype!).

Dan: your new project is georgous to look at. If it sounds at all like the one you crafted for David...it will be the total package. I can't wait to play the finished instrument.

HAPPY NEW YEAR to All!

Will1717 - Posted - 12/31/2009:  15:41:01

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Dan:

All I can say is, that's one amazing banjo! You may have forgotten but the reason that we met many years ago at the SPIGMA convention in Nashville was beacuse I spotted your banjo out in the Sheraton Hotel Lobby. You were probaly the only guy there with an open back banjo and it had this amazing inlay job up the fingerboard. I approached you to inquire about the amazing pearl work, and we chatted for approx. 20 minutes about banjos and inlaying. Everytime I think of you I can remember that particular banjo. Talk about being embarassed at the time. You stuck the banjo in my hands and asked me to play, not realizing that I'd only started to learn clawhammer style and had a grand total of 1 month experience! You naturally pcked this up immediately and gave me a free lesson in the lobby! Good memories for sure! Your work still amazes me and leaves me very humbled to say the least. That meeting back in Nashville had a lot to do with getting me back into building banjos after I got smashed up. Amazing how people can affect your life!

Again, that's one beautiful banjo, as all your creations are! Very best of the New Year Dan!

Bill Rickard

DanKnowles - Posted - 12/31/2009:  16:48:59

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To all of you wonderful people,
Thank you, I am humbled at your kindness and generosity.

Jason,
You could always send your address and hope.

Bob,
I hope that it (this banjo) might make a smart car!

Bob Atkinson,
I'll try to keep these posts a'comin...y'all make it worthwhile.

John,
I'm looking forward to hearing what it sounds like in your competent hands.

Bill,
I'm blessed having you as a friend. I count it as one of the high points of my life. Thank you

Old Chorizo - Posted - 12/31/2009:  17:07:34

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Dan,

Hope has never really worked out for me! :(

My momma always used to tell me "You can sh-- in one hand and hope in the other, see which one fills up first?" haha

Looking forward to more pictures!

DanKnowles - Posted - 12/31/2009:  17:29:33

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New Years Eve 2009

Details, Details
Today I inlayed the man on the skiff, the remainder of the trees, silver pole lines, the Lee's flag and cleaned fret slots of glue.

Here are some photos of the silver pole inlaying. This is a bit different as the is no router used. The cuts for the silver wire is quite shallow. This wire I'm using is silver I think is 28 gauge. First a pencil lay out mark is made followed by (above) a cut from my sharpest knife. Next by pulling the knife backwards and sideways the slot is widened (below).



Next glue (from my trusty pipet) is sparingly applied.



Using a small jewelers chasing hammer, the silver wire is gently tapped into the groove.



The wire is cut to length and tapped home.



Below is the first step I use in clearing the fret slots of glue. I put some propane fire on a small flat knife. I use to do this with a saw but it was hard to follow the old slots, so I went to this method.




Then the hot knife is pushed down into the slot melting the glue and beginning to open the fret slot.



Next a .015 saw cleans out the residue.



Well here is the Robert E. Lee steamboat at the end of todays work. New flagpole and all.



Thank you each and every one fo looking in at this New Ebony Banjo. May you all have a blessed 2010. Feliz Ano Nuevo

DanKnowles - Posted - 12/31/2009:  17:32:12

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Jason,
With my Mom, it was coffee... but it always an out from between my fingers...and burnt my hand!

devoall - Posted - 12/31/2009:  19:10:01

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Dan, this is ridiculously great. It's so great to be able to watch a banjo being built from an idea to a finished project. Thanks for all the great pictures. One day i'll be able to use all of this info to build my own banjo!

DanKnowles - Posted - 12/31/2009:  20:31:08

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Jim,
I hope this will help. Happy New Year

jay_m - Posted - 12/31/2009:  22:23:47

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this thread should just straight up be its own, stand-alone web page or something. such a cool read.

DEmery - Posted - 01/01/2010:  05:40:24

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Good Moring. My friend Mister Balch and I have been in discussion about yesterday's work and we can add nothing to the kind words offered by the readers...but it is a daily process of reviewing at this point. Question. Are you engraving the steamboats and contrasting with ebony dust in the detail? In closeing, impressed with the flag pole in silver wire. David

arnie - Posted - 01/01/2010:  06:03:41

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Wow! Do you per chance know Grit Laskin? You should send him pics of your amazing work!

dbrooks - Posted - 01/01/2010:  07:01:01

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Each update offers its own revelation, Dan. The vision, the design, the sure-handed execution and the combined devotion and delight in your work are stunning.

David

Couchie - Posted - 01/01/2010:  08:58:57

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Love this!

Stringbean45 - Posted - 01/01/2010:  14:55:01

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Hi Dan,
Please add me to your list of watchers. I have been watching from the start, and am amazed every day at your superior workmanship, and artistry.

Thanks for letting us all in on this banjo build,
Don

DanKnowles - Posted - 01/01/2010:  17:11:30

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Jay,
I am thinking about putting all of the photos I've taken (posted or not and there are hundreds of them) of this project along with the writings from this post (when the banjo is finished) Burn it all to a CD or DVD so folks could look at it as a whole. Is anyone interested?

DanKnowles - Posted - 01/01/2010:  17:17:16

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David E,

What I am doing with the adding the black to the turquoise is sort of like engraving. Just not quite as delicate. In today's post I start the preparations for engraving the peghead.

DanKnowles - Posted - 01/01/2010:  17:23:07

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Arnie,
I don't know Gritt personally. I met him once at a show. Still I have admired his beautiful work from afar. His and Larry Robinson's work is a continuing inspiration for me.

David B, Do and New Don,
Thank you ever so much. And New Don count yourself as added!

Will1717 - Posted - 01/01/2010:  17:40:01

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Dan:
Your thoughts of putting all this + additional photos on a CD or DVD is a terrific idea! There's just nothing like this on the market. I'm certain that it would be a fantastic seller! Put me on as the list as customer #1.

Bill Rickard

DanKnowles - Posted - 01/01/2010:  18:01:46

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Being as today was New Years Day, I didn't spend much time at the shop...but here is what I did.

This photo shows the inlay overhand on the peghead. This overhang has bugged me for a while so I figured today would be the day that it vanished.



I grabbed up my handy dandy Moto tool stuck a little barrel sanding drum on it and went to town. In a jiffy the inlay was flush.



Next there is another inlay overhang down near the heel so I used a hand held routing jig to get rid of most of it.






Then I finished the clean up job with a mill file.



Next I sanded the fingerboard with 400 grit on a glass sanding stick.



Then I sanded the peghead to 2000 grit in preparation for engraving. The inlayed material must be slick, slick, slick or your graver might follow a scratch (ruining your piece) and the filler will show any scratches. After all, engraving is just the art of adding scratches to your work!



Lastly today I installed the new Bill Richard titanium White Lady tone ring on my Pharoah banjo... more on that later!

Will1717 - Posted - 01/01/2010:  18:14:24

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Dan:
You got me filled with suspence about that titanium ring! Did it sound any good or was it a flop???

DanKnowles - Posted - 01/01/2010:  18:30:02

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Bill,
For further details, check your inbox.

arnie - Posted - 01/01/2010:  20:48:31

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Dan, when you are done with this banjo, would you mid sending Grit Laskin pics of your work? If so, email me & I'll give you his email information - I was speaking with him tonight & happened to mention this project of yours & I'm sure He'd like to see it.
Arnie

Ol Lefty - Posted - 01/02/2010:  05:12:19

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As would Craig Lavin. I am inlaying a flying/landing bald Eagle on a peghead and Dan inspired me to break out sterling wire for a branch under the talons.It has been awhile since I did this on Kentucky rifles-luckily a branch has no formal shape and CA glue means I do not have to undercut it for security. We used to undercut a smaller groove along and under one side of the inlay groove groove and then hammer it in-expansion would lock it in.

Also, please, a bit humorous note-in the future when I say something ornery or stupid, I request a "pass."I ask, since my "wonderings" about what to do with my small, precious stock of G. Ebony fired up this fine man and artist to join us and teach us. "Just sayin'." He even invited me to call but so far I have been shy(I know, I know)- I hesitate as one would just dropping by Rembrandt van Rijn's studio to chat<G> Ol'Lefty

DanKnowles - Posted - 01/02/2010:  11:32:18

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Arnie,
I'd be proud to, Grit is one of my lutheri heros.

Mike,
Don't feel backwards about calling, I most certainly am not Rembrandt... although the thought is quite nice.

DanKnowles - Posted - 01/02/2010:  20:47:38

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Today I figured I'd brag on one of my favorite students Kevin (Steve) Baily. He's been taking private inlay classes from me and is doing great!



There's Kevin looking up when he should be looking down...
Here he's engraving a piece that his daughter designed. A fairy or an angel.



Here are a couple of shots of the finished piece.



What's cool about this is that it is tiny, about 3/4" tall.

DEmery - Posted - 01/03/2010:  06:36:02

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Happy New Years Dan. Have you settled on the shoes and hardware (I know the tone ring will go through a test process) that will compliment the rim art? Seeing how the steam boat anchors the center of your fingerboard - it will be intereting to watch where the rim art is headed. While John Balch was at our home we monitored the work done in recent days. As they say "the devil is in the details." Your detail work has framed the art work. I will keep watching.

By the way, how do you like the piece of art framed in my homepage window. I know the artist if you are interested in his work.

David

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Edited by - DEmery on 01/03/2010 10:13:28

jay_m - Posted - 01/03/2010:  15:39:21

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you know what? this thread has the best kind of effect where creativity is concerned: the work on both banjos is at once so amazing that it both inspires me to do much better work than im currently doing AND to basically give up because nothing i make will ever approach this. its spectacular and wonderful. i hope this banjo takes years to make so this thread won't end too soon.

DanKnowles - Posted - 01/03/2010:  19:54:30

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David,
ear to you too. I am still thinking about designing and casting shoes for this one. Although recently Bill Richard sent me some pictures of a new shoe he is making. I think that I could maybe sculpt these shoes into something fitting. It seams that the fella who as been doing my plating has gone out of business, so I have another hoop waiting.

I really like that artwork. Oddly I knew one of that artists teachers who told both of us, "The god is in the details." All those dots...

DanKnowles - Posted - 01/03/2010:  19:58:07

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Jay,

Grit Laskins work does the same thing to me. It is both a whip and a carrot. Practice allows the carrot to come nearer.

Gomer - Posted - 01/03/2010:  20:04:03

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This is a lot like following Tiger's mistresses. Every day there's a new sexy picture. Great inlays!

DanKnowles - Posted - 01/03/2010:  20:15:25

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Tom,
I always wondered who it was doing the stocking of Tiger's mistresses...
Thanks

Ol Lefty - Posted - 01/04/2010:  04:39:16

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Dan-does your business card draw on the old "Pinkerton's?" "We never sleep" with a wide open eye pictured? O'L

DanKnowles - Posted - 01/04/2010:  18:43:58

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Mike,
I hadn't thought of that ...maybe on the next card. I've always been fascinated with eyes.

rln5754v - Posted - 01/06/2010:  07:07:48

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Brother Dan !!!!!! My heart skipped a beat ( just like my play'n) when I saw the River Boat Inlay..... W O W !

Its Beautiful !

Ron

DanKnowles - Posted - 01/06/2010:  16:46:44

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Ron,
Thanks , I always wondered when my favorite video maker would look in (this is the fella that made my Sally Ann video), I'm glad you are here.

DanKnowles - Posted - 01/06/2010:  17:49:40

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Today, after several days of being sick and out of sorts I stated the engraving. Engraving is a enjoyable quiet work. Here sort of like pen and ink drawing in the details that help us know what we are viewing.

Below are some of my tools. Some of these are commercialy made gravers, some are made from steel rod and some are made from old jewelers files. Most of the handles I made. I'm not to concerned with shape, just that they are small enough to fit in my palm, enough mass to give me something to hold on to and just the right length. I like them to lay in the center of my palm with the point at about the tip of my index finger.

The other two pieces there are an old and very fine oil stone and an old oil can that I am partial to.



Here I am sharpening a graver. This is probably not the best photo to illustrate the steps in sharpening as it was made during the third sharpening step. Still sharpening is one of the most important things in pearl engraving. Dull tools make good work impossible. I will shoot some better photos and do a more complete explanation in a later post.



Here is the peghead (before I start messing it up!) and further up the neck is a print of the photographs of the various models fo this work. I'll use these photos for reference as I engrave. I've decided to begin the work on the center adult male figure.



Next I freehand draw shape and shading (for reference) on the pearl.



Here I'm engraving shading on the neck, I have already started the hair. You can see here how I hold the graver. I will either hold it like this and push the graver or (using another tool) pull it much like a scrimshaw artist.



Here I'm filling the graver marks with an oil crayon. I've seen how Grit Laskin has his own special filler and I guess I'll try it out when this one is finally gone. I'll fill a bunch of times, checking the progress of my work.



Here it is after application, next I'll rub it into the graver marks with my finger.



Now I'll rub it clean with a paper towel.





Here I'm using a very pointed graver in a scrimshaw manner to add detail and shading to the vest.





Finished for the day.

bosborne - Posted - 01/06/2010:  18:02:03

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quote:

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Finished for the day.

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Let me be the first to say ... amazing.

DanKnowles - Posted - 01/06/2010:  18:34:41

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Brian,
Thank you for your kind comment. It's funny, looking at the photo I see a bit more work yet on that poor fella.

DanKnowles - Posted - 01/06/2010:  18:54:06

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Richard Brown (BordertownBrown) a fine Texas banjo maker just introduced me to a new tuning machine called Pegheads. The tuner looks like a traditional violin tuner but is in fact a 4 to1 planetary machine. I'm thinking of using these on this instrument both because of the reputed quality and because of the almost nonexistent footprint (they won't cover up the inlay. Has anyone used these?

Gingery - Posted - 01/06/2010:  20:30:48

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That inlay is inspiring

Bagpussfrog - Posted - 01/07/2010:  01:24:38

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Yowser! Dan, that really looks awesome! If I ever summon up enough money for another 'jo, I'd love you to build me a banjo - you're a true artist.

Viper - Posted - 01/07/2010:  08:14:57

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quote:

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Originally posted by DanKnowles

Richard Brown (BordertownBrown) a fine Texas banjo maker just introduced me to a new tuning machine called Pegheads. The tuner looks like a traditional violin tuner but is in fact a 4 to1 planetary machine. I'm thinking of using these on this instrument both because of the reputed quality and because of the almost nonexistent footprint (they won't cover up the inlay. Has anyone used these?

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First of all, the engraving looks wonderful. It's really neat to watch this process.

I don't have personal experience with the Pegheds, but I've read about a few makers who seem to swear by them. One who comes to mind is Jeff Delfield (banjohangout.org/myhangout/hom...?id=28714) of Deep Creek Strings. Check out (deepcreekstrings.com/2009/11/t...o-13.html). I think the Pegheds would look really nice with your banjo. Cheers!

Delfield - Posted - 01/07/2010:  08:45:34

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I've been watching this thread from the get-go. Thank you so much Dan for sharing all of this. Speaking as a serious hobby builder, your posts have been invaluable.

I've used the Pegheads a couple times and I love them, but I'd think that the authority on Pegheads (at least among professional banjo builders) would be Chuck Lee. He said that he's installed over 200 sets in this forum: banjohangout.org/topic/164335

I think you're right Dan, the Pegheads would obscure your art less than normal tuners.

Jeff

jbalch - Posted - 01/07/2010:  11:34:17

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Magnificent!

Dan:

Is this the engraving filler you mentioned? I need something to re-color the engraving in my fancy Bart Reiter banjo. I've looked at this product before...but not yet ordered any.



JB

GSCarson - Posted - 01/07/2010:  15:33:43

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Great work and photo sequence Dan, really enjoying watching this build come together.

John, Laskin's filler is probably the easiest way to fill those engraving lines, it works quickly and well.

Glenn C.