DanKnowles - Posted - 07/22/2010:  20:12:34

NEXT PEGS

If you remember from our earlier posts, I made only two tuning pegs. So before I can go ahead an finish putting the banjo together and stringing it up I need to arise from my lazy butt and create the other three.



Here I've put the blank on the small lathe and am roughing it into round with my large gouge.

Because I want the pegs to have the feel of having been hand made on a treadle lathe, I'm not using a set pattern or "preacher or Judas stick". Instead I'm holding one of the finished pegs next to the spinning piece and just eye ball marking it.



Here using a very narrow parting tool I mark the cardinal points.
Yes all of the feather points....






Using a digital dial caliper the various arias of the pattern peg are measured to the nearest 100 Thousandth.
.0o0o0o1



Milling the pip.



One of my favorite sanding devices on the lathe is used sanding disks. Here I'm sanding with 400 grit.



Here the first one is finished and is coming off the lathe.



In one session I turned all three remaining pegs and one dud. This dud piece must have had a hidden crack, for the knob just blew apart as I was turning it. Here they all are.

BourbonBandit - Posted - 07/23/2010:  06:13:32

I'm late to this thread, but have spent the morning reading and following. I am amazed. Fantastic work.

Steven M - Posted - 07/23/2010:  14:14:09

Dan, did you use tourmaline as your 'oxidising' ageing solution, if not that works really well also.

DanKnowles - Posted - 07/23/2010:  19:45:05

THE RETURN OF THE PEGZZZZZZZZZZZ

Here we are back with the peg making again today. I will be finishing their shaping in this post.

First I've got to cut off the top and the bottom, it's all peg waste anyway. Here I am using the band saw to accomplish this.

I wonder if I bragged on this fine Grizzly saw they might give me a discount on the __________ that I've been wanting?





Now I shape up the peg ends on the belt sander.



Now I sand the finger holds. Basically I'm using the sander to grind away all of that excess wood. It leaves me with a nice indentation. This was one step that I missed showing in the earlier post on peg turning. Here I didn't get a great photo but maybe it will give the idea.



Here is the whole bunch, shaped.



Using a violin peg shaper. It is kind of like an old fashioned pencil sharpener. Each of the pegs are shaped with this so that their taper matches that of the reamer which is used to true the peg holes.



Here they are in the 1850's banjo.

DanKnowles - Posted - 07/23/2010:  19:58:55

Brett,
Thanks for looking in. I'm glad you've enjoyed it. Comments like yours makes this worthwhile.

Steven,
No I haven't. Currently for brass & copper I'm using an agent that I get from Rio Grande that I suspect is mostly liver of sulfur. For steel and iron I use salt water. It gets the job done and quick.

Carl Ball - Posted - 07/23/2010:  20:49:53

What a joy to watch this work and attention to detail.

Steven M - Posted - 07/24/2010:  03:34:42

To age and darken a metal we use tourmaline solution. It acts in seconds! It is however being withdrawn from use due to environmental issues but with judicious use it is fine.

Your method looks great also and does the trick.

DanKnowles - Posted - 07/24/2010:  19:26:03

Carl,
Thank you . I'm glad you are enjoying the post.

Steve,
Thanks for the advice. I wish I could try some of that elixir!

DanKnowles - Posted - 07/24/2010:  19:56:15

BURNING NEWS
BANJO PEGS AFIRE!

Friends,
Romans
and fellow banjo -a-holics...

Today I'll burn the pegs and stick 'um home on the 1850's banjo. We want them to look just right.

First I lighted up my trusty propane torch and grabbed up a peg.



All of the pegs have been shaved to fit a single peg hole. I remove only one peg at a time to maintain orientation. When whatever operation has been completed the peg is returned to its hole. Each of the holes have been lightly reamed to true the pitch.




Each peg is dyed with leather dye. First medium brown, dark brown then black.



Then it is buffed with my Dremel. No compound is used. Just a bare buff.



Checking the fit.



Now that the pegs are all fit, excitedly I start the bridge. It is to be made from a piece of quarter sawn spruce. This piece came from a 100 year old piano soundboard. I have been making spruce bridges for my minstrel banjos for years after reading that many original bridges were so made. I love the sound of spruce. It seams to be warmer yet clearer than maple, without any harsh overtones. I've made a few of these for steel strings but the quickly fell apart under the pressure.





I made a bridge pattern following a drawing posted earlier in these posts. The pattern was made by folding apiece of card stock and cutting it out.



I drill the end holes first.



Then cut the inside shapes.

DanKnowles - Posted - 07/25/2010:  15:00:39

REPRODUCING 1850

I am currently considering building reproductions of this 1850's beauty. I'll probably be making them in both a new (non- distressed) and relic (fully aged) If anyone is interested in having one built please contact me.

FINISHIN' THE BRIDGE......
aw nutz!

Continuing on with bridge construction, we prepare our pile drivers. The steel is already firmly planted in the footings and the concrete is ready to pour. Tampers have been brought in from nearby Porta De Leion and are currently waiting on the wharf for the towboat and barge to retrieve them...



What? Wrong post. Oh no I am so sorry. I thought this was bridge building 101. How embarrassing.

Give me a quick kick in the seat of the pants and I'll be back on track.



Ok, here we go...
The bridge has been fully cut to shape on the band saw. Then it is sanded to thickness on the belt sander. If I were doing this more period accurate I'd grab up one of my Grand dads planes ad give it a quick swipe.



Then placing the bridge in the vice and using a small file I clean and smooth all of the rough edges.



And cut in the string notches.



Next it gets a good sanding and then it is treated with powdered graphite and tea to give it a nice patina.




I ordered some gut strings from Dr. Horsehair music for this banjo. Bobs Minstrel strings are right nice. Other than the silver wound forth string, they all look old. I don't mean old like worn out or antique they just have a nice archaic feeling about them. I'm not sure I'm explaining this well, but the are very nice..

Here I'm starting to attach them to the tuners. This is when it starts to get exciting. This knowing that soon I will hear a voice not heard for a long , long time.





And all on.



At this point I tuned the banjo and called Paul (its owner) on the phone. I asked, "Would you like to hear something?" and played several minstrel tunes. It was an emotional moment for me hearing this sweet, full, long silent voice raised in song. I suppose I played her for 5 minutes. Then we talked about her voice and rehashed the project in general.

I set the banjo down in her box.

We talked some more.

Then POP a loud snap came from the banjo.

Whats happened? Have the joints given way? Is there just kindling left? Several moments of grave fear went by. Anxiously I searched for the cause. Then I noticed a loose aria of the head. Had the head tore? No instead one of the original bracket nuts decided to self strip. The soft brass had given way.

So now I needed to make another one.

Bad news you say... nope good news! Everything had held, no joints opened! The extra good news was the unlike the first J-hook which was missing a nut, this one has a standard thread pattern.

So this time (just in case) I laid out, drilled and taped for two nuts.

Edited by - DanKnowles on 07/25/2010 15:05:34

chadp - Posted - 07/25/2010:  15:41:30

are you all done now?! i wanna hear it!

jbalch - Posted - 07/25/2010:  16:23:56

quote:

---

Originally posted by chadp

are you all done now?! i wanna hear it!

---

Carl Ball - Posted - 07/25/2010:  20:52:35

Me three. I would love to hear a sound clip from this beauty.

XXXris - Posted - 07/25/2010:  22:03:13

Four!

Green_98 - Posted - 07/26/2010:  08:01:43

I'll be #5

Tackhead - Posted - 07/26/2010:  08:49:25

Regarding the string notches--did you simply use a trianglular file to create the notches? All the same width and depth? Thanks.

~John in Tallahassee, who needs to make a bridge for his Wunderlich Tackhead

Jonnycake White - Posted - 07/26/2010:  10:19:53

Gotta love those nuts!
I will add my voice to the clamor for some sound files.
I'd also like a critique of the gut strings - how much different do they sound compared to Nylguts? How fast to they wear out? and so forth.

DanKnowles - Posted - 07/26/2010:  19:23:45

Chad, John, Carl, Chris, Patrick & Jon,

Some MP#'s are on their way. I should have them up in the next couple of days.

John,
I will use a pear shape, three corner or knife edge needle file or a very sharp knife depending on my mood. Most violin makers I know use the knife technique. If you'd like a bridge for your banjo feel free to call me.

Jon,
I like the sound of gut much better than nygut. It seams thicker, warmer and more present. I have used both and the nylon seam to last a bit longer (before breaking or fraying). Perhaps some of the other folks can weigh in on this one and keep me from being the lone voice in the wilderness.

jbalch - Posted - 07/26/2010:  19:47:58

I really prefer Gut over nylon. I love the sound and feel of the real thing! This great banjo deserves nothing less (IMHO).

I have Gut strings on two banjos by Jeff Menzies and one by G. Wunderlich. I play them around the house a lot (don't take them out much). For that use, Gut has been very reliable.

Edited by - jbalch on 07/26/2010 19:49:25

DanKnowles - Posted - 07/26/2010:  19:49:12

PHOTO TIME

After completing the banjo several evenings were spent playing this beauty. I was able to take her into the studio and make a few recordings. I'll post these in the next day or two. Tommy Ogle, Jonathan Farrell and I played her for several hours and had a great time inspecting her thoroughly. Jonathan has handled several Jacobs banjos and he agreed with Ed Britts contention that this banjo is probably a Jacobs.

"Nuff said, on to the photos.

Mr100BoJangles - Posted - 07/26/2010:  20:40:01

She's a beauty! Can't wait to hear what she sounds like.

Castania - Posted - 07/26/2010:  22:58:38

Ditto that. It looks great -- no doubt -- but without sound . . . it's just a museum piece. I'm looking forward to hearing this long silent voice.

Steven M - Posted - 07/26/2010:  23:50:45

WOW, as good as new, I mean old! Fantastic work that man, a round of applause followed by a sound file please!

Bluegrass-Gibbs - Posted - 07/27/2010:  02:58:18

one word:
AWESOME

aj_fuller - Posted - 07/27/2010:  05:57:28

Dan,

It looks amazing! Can you comment on what aging processes you applied to the bridge between the last bridge building photos and the final result in the most recent set of pictures? I presume you did some scratch and dent work and perhaps some ebony dust as with the other pieces, but would be curious to know for sure - it looks nice and old!

Thanks!
A.J.

Jim Cannon - Posted - 07/27/2010:  07:54:57

Dan, it has been fun following this thread. One of those things you wish wouldn't come to an end. Thanx.

Rowland - Posted - 07/27/2010:  08:51:15

Beautiful, inspiring. I'm dumbstruck. I can't wait to hear it. I would love to hear more about a reproduction of this banjo. I'd also love to see that process documented here (hint,hint) Thanks for a GREAT thread !

Green_98 - Posted - 07/27/2010:  08:56:50

Looks amazing! I can't wait to hear it

Mark Johnson - Posted - 07/27/2010:  09:33:39

This might be the greatest thread ever. It's been a true pleasure to tune in to. I'm really floored by your work, Dan, and admittedly a bit jealous.

Really neat,

Mark

XXXris - Posted - 07/27/2010:  12:51:27

Nice job! Thanks for posting all this. I often logged on just to see if there was an update to the thread. I liked the gradual drama, punctuated by "He poked a hole in the head!" and "He cracked the tailpiece!" Hope you do another thread sometime.

DEmery - Posted - 07/27/2010:  17:08:17

Dan, I always enjoy watching your work and the results are always on the mark. The 1850 ended up as you intended I think; it is back together,undisturbed, and doesn't appear in any way other than original. Great work Dan. David E.

Bob Robert - Posted - 07/27/2010:  18:29:43

Looks great!
C'mon, we need some sound files! You're killin' us here, Dan!

DanKnowles - Posted - 07/27/2010:  20:22:24

THANK YOU

First to Michael,Ken, Steven, Becca, Al, Jim, Brad, Patrick, Mark, Chris, David Emery, Bob, John Balch, Ed Britt and the rest of you wonderful folks who have stuck with me following this thread I THANK YOU FROM THE BOTTOM OF MY HEART! It is you folks who make doing this worthwhile.

Tonight will be my next to last post on Restoring 1850. This would have been my last post had I not mis-saved the sound files I was going to put up tonight. So I'll do better and post them tomorrow. Also if anybody knows and would tell me how to convert Quicktime files to MPEG's I have some beautiful footage of the Jacobs being played Minstrel style by banjo master Jonathan Farrell.

Next to my friend Paul Murphy,
Thank you for trusting and allowing me to handle this precious beauty. I treasure this fact above all else. I hope it meets your expectations.

MY NEXT POST will start soon. I have two projects which I hope you will find interesting.

One is a 9 STRING HARP BANJO.
This exciting exploration in sound is still in the planning stages, but I should be constructing it soon.

The Other may be called BUILDING 1850.
I will work through all the steps of building an accurate reproduction of the 1850's Jacobs banjo. Here I will detail all the steps including aging a bridge.



MORE PHOTOS









Here is Jonathan Farrell whackin' out some beautiful Minstrel Banjo on the 1850's Jacobs.



Here it is being packed up for her long ride home.

Castania - Posted - 07/27/2010:  22:58:33

Dan,

I think Mencoder will convert Quicktime files to Mpegs. It's a command line program however; no slick windowed interface.

I have it for Linux -- don't know if it works with Apple or Windoze. It's a free download, but it may require some tweaking.

Ken

BNJOMAKR - Posted - 07/28/2010:  03:40:40

Beautiful job, Dan... can't wait to her her talk to me!
Marvin

steveh_2o - Posted - 07/28/2010:  05:49:08

Dan,

If you have a youtube account you could upload them in most any format and post us a link.

Steve

Jonnycake White - Posted - 07/28/2010:  08:37:00

Simply a great, great job. Thanks so much for posting all this, Dan.

riphalman - Posted - 07/28/2010:  13:54:37

Can't wait to hear that pre-(civil)war sound!

DanKnowles - Posted - 07/28/2010:  16:24:50

Ken, & Steven Thanks for the advice. I'll look into youtube posting.
Marvin, Jon and all the rest of you folks TONIGHT IS THE NIGHT!

DanKnowles - Posted - 07/28/2010:  16:43:14

A little photo given me several years ago by Calvin Miner. It is sort of a tease isn't it?



And now the MP3's.

This was the first recording I made on the Banjo it's called the OHIO RIVER CHUCKLE...somehow it seamed to fit.

banjohangout.org/myhangout/mus...id=44416#

And now Peter David Quinn Boettcher's immoral CHANDANS WALKAROUND.

banjohangout.org/myhangout/mus...id=44416#

I DO HOPE YOU'VE ENJOYED RESTORING 1850. I LOOK FORWARD TO BEING WITH EACH OF YOU AGAIN SOON.

THANK YOU SO MUCH.

Yours,
Dan Knowles

GrassJam - Posted - 07/28/2010:  18:51:13

Dan, those two cuts are simply amazing! Talk about going back in time... I felt like I was there for a brief moment. What a thrill it must be to put an old one like this back together again and then get to play it for the first time in probably a hundred years. I can't thank you enough for everything that you've done and I can't wait to actually get the finished product back in my hands again.

Paul

BNJOMAKR - Posted - 07/28/2010:  19:13:31

Thanks Dan... She speaks volumes.... !

Castania - Posted - 07/28/2010:  19:31:23

And to think . . . this is the sound that most people initially associated with the word "banjo." And, from that, banjo playing became embedded in American cultural bedrock. It's humbling just to hear it.

I look forward to your next project, Dan. Thanks!

Ken

Bob Robert - Posted - 07/28/2010:  20:02:46

Wow, that is cool. Like bringing a piece of history up to our time.

By the way, the first listing in your music files for Chandan's Walkaround includes the sentence, "This instrument may be found for sale in the BHO classifieds."

I read that and thought, you've got to be kidding me! Then I saw the second listing . . .

Edited by - Bob Robert on 07/28/2010 20:06:10

GSCarson - Posted - 07/28/2010:  20:47:33

Great job once again Dan, please keep em coming! She sounds great too.. Glenn C.

Carl Ball - Posted - 07/28/2010:  21:01:14

Imagine what that banjo has "seen". It is the roots of all our presnt day banjos. It was a really different world when that was first played. A much more innocent age I think.

Couchie - Posted - 07/29/2010:  05:31:22

The same amazing work that we've come to expect. Thanks Dan for the wonderful insight into this instrument.

Tackhead - Posted - 07/29/2010:  06:13:50

Thanks for taking all of us along on this incredible journey. Now, how about making one from scratch and documenting it

~John

AlanQ - Posted - 07/29/2010:  06:43:18

Hi Dan,

I am new to the banjo and late to the party, but I must say that the afternoon I spent reading about your restoration of this beautiful piece of history has been truly inspirational to me, and has opened up a whole new area and depth of interest. Your craftsmanship is superb and your attention to detail and senstitivity to the historical aspects amazing!

The preservation of the character and patination of this instrument against the current trend of grinding, acid-cleaning and over-polishing to make antiques "like new" is most cool.

Terrific job and thank you!

Alan