DanKnowles - Posted - 01/10/2011:  18:35:58

RUBBING IT RIGHT

Tonight I'll continue fooling with the (perch pole end (dowel stick in old style).

First I removed the neck from the rim. And sanded and filed all of the saw kirfs from the end of the stick. By the way it got sanded to 600 grit. I'm preparing it for some awful abuse.





Then I started burnishing the ends & sides & top & bottom.






The neck back in the rim with just a few bracket shoes stuck i, just to see how it looks.

Will1717 - Posted - 01/10/2011:  22:02:50

Dan:

We're driving down to SPIGMA this Feb. and will drop by for a visit if possible. I was thinking that if I brought those rims and parts down with me we could drag them down the highway behind the van and save you all that work on the next build. Toronto to Nashville should beat them up pretty good!

Bill Rickard

DanKnowles - Posted - 01/12/2011:  20:05:27

Bill,
I look forward to your visit with anticipation! I have been hearing so much about your new spun-over rims that I can hardly wait to see them!

DanKnowles - Posted - 01/12/2011:  20:14:37

This may be a bit premature, but I'd like to give a heads up to all you good folks that have been following this post. Bill Ricard and I are thinking of doing a banjo jointly. Bill would do the basic design and building work ie the rim neck shape and etc. an I would do the decorative design ie inlay and engraving both metal and pearl. We could then create a post to follow this process.

What do y'all think? Any ideas for this project? Anyone interested?

Paul R - Posted - 01/12/2011:  20:46:58

quote:

---

Originally posted by DanKnowles

This may be a bit premature, but I'd like to give a heads up to all you good folks that have been following this post. Bill Ricard and I are thinking of doing a banjo jointly. Bill would do the basic design and building work ie the rim neck shape and etc. an I would do the decorative design ie inlay and engraving both metal and pearl. We could then create a post to follow this process.

What do y'all think? Any ideas for this project? Anyone interested?

---

BNJOMAKR - Posted - 01/13/2011:  02:29:09

Great! Would it be called the Rickard-Knowles, or the Dan-Bill, or the Tennesee-Candaian, or.... ?!

Viper - Posted - 01/13/2011:  07:17:59

quote:

---

Originally posted by DanKnowles

This may be a bit premature, but I'd like to give a heads up to all you good folks that have been following this post. Bill Ricard and I are thinking of doing a banjo jointly. Bill would do the basic design and building work ie the rim neck shape and etc. an I would do the decorative design ie inlay and engraving both metal and pearl. We could then create a post to follow this process.

What do y'all think? Any ideas for this project? Anyone interested?

---

Steven M - Posted - 01/13/2011:  13:52:11

quote:

---

Originally posted by DanKnowles

This may be a bit premature, but I'd like to give a heads up to all you good folks that have been following this post. Bill Ricard and I are thinking of doing a banjo jointly. Bill would do the basic design and building work ie the rim neck shape and etc. an I would do the decorative design ie inlay and engraving both metal and pearl. We could then create a post to follow this process.

What do y'all think? Any ideas for this project? Anyone interested?

---

DEmery - Posted - 01/13/2011:  14:09:55

Steven, as the owner of several of Dan's fine banjos (several with Bill's components) and soon to receive the initial 1850's Jacobs you have watched in this thread...I recommend that you jump on this project with both feet. I bet Dan and Bill would be delighted to make it your banjo. David E.

muleskinner63 - Posted - 01/13/2011:  14:27:16

Yes Iam , i`ll speak with you soon thank`s for the thread dan it is fun to see thing`s most don`t get to see Great job !

Crowman - Posted - 01/13/2011:  16:43:00

Yes Sir I am interested as you both are masters at what you do. Would love to follow the progress and would also love to see a "Kit" version later down the road for us that are not masters yet. You and Bill working together is going to be something for us all to enjoy and learn from. Both of you are great for sharing your building knowledge with us, as I soak up as much as I can, cause one day I will get back in the shop when things improve here at home. Please count me in!

DanKnowles - Posted - 01/15/2011:  18:00:39

THE LIGHT AT THE END OF THE TUNNEL...
IS A TRAIN

We are heading towards the finish line now.... I can almost hear the banjo sing! This is where for me the project begins to get exciting.

Tonight the head....

Here I am beginning to make the flesh hoop. I'm making this from 1/8" steel rod. I have this rod roller that I bought at Harbor Freight. There is a lot of stuff at Harbor Freight but one has to be careful because the quality is quite uneven. This metal roller is quite good for light metal. I don't remember how thick a material it can roll but for flesh hoops it is wonderful!

To use this tool well it is first clamped to the bench.



The rod is rolled and then checked for size.



Back in the roller to make the hoop smaller.



There we go... it fits.




Here I am marking the length so it can be cut.



Cutting...
(not barking spiders)



Fire Time!!!!



Cooling off.



Grinding the joint smooth. Sorry about this photo, it was the best of the lot, still it does show sparks.

DanKnowles - Posted - 01/15/2011:  18:33:05

[size=6RICKARD-KNOWLES

BANJO PROJECT][/size=6]

I am feeling quite excited by the prospect of working with one of my hero's in this banjo making business Bill Ricard. I have used his wonderful hardware in my banjos for several years and in my humble opinion they are the finest made since the "Golden Years" of Fairbanks, S.S. Stewart, Cole, Bay State, Farland and Vega ca. 1890 - 1920.

Here is a photo of a banjo that I built a couple of years ago with a cocobolo rim and his 'raw brass' hardware.




We are playing with the idea of creating a completely NEW banjo model featuring his newly develouped Ricard 'spunover' rims. By all reports these rims are absolutely amazing.

I don't have any photos of the rim to show but here are a few other photos of Ricard parts that I have used.

Again 'raw brass'. I can't get enough of this stuff.






Silver plated.




Nickel plated.



A shoe which I engraved.







And lastly a bracket nut which I doctored.

jbalch - Posted - 01/16/2011:  07:03:24

Dan and Bill: ...lookin' forward to more about the Knowles/ Rickard collaboration.

DanKnowles - Posted - 01/16/2011:  17:46:54

DETOUR

I got to lookin' at the rim and I feel it needs just a bit more. I want to replicate the water damage the original sustained. So after thinking and figurin' quite a bit on it I got out some white slip that I had made up for ceramics work and began painting.





Using a lightly dampened paper towel I selectively wash som back.



Painting it on the lower inside.








Here is the final result. I'm not at all sure that I am happy with the result... WHAT DO Y'ALL THINK?

Stringbean45 - Posted - 01/17/2011:  13:53:02

Hi Dan,
I think you can do better. Doesn't look like you are finished with it yet. Put the torch to it. Looks to me more like it was in a room being painted, and caught some of the splatter.
Just my opinion,
Don

Ron Ortegel - Posted - 01/17/2011:  14:10:40

I can't wait to see what's next.

timmo_1949 - Posted - 01/17/2011:  16:17:50

It strikes me as overdone, i.e., a little too white. I say that without having the gumption to go look at the original. I wonder what just plain water might have done.

Tim Smith
savethebanjos.com

Karen Kruske - Posted - 01/17/2011:  16:39:31

Well, if you gave me the choice of a brand new banjo or one you just finished that looks old and weathered, I'd pick the brand spankin' new one, so I guess I'm not feeling too well when I look at what you have done to her. :-)

Have to say that following how you have made this banjo has been very interesting and enjoyable. Thanks for sharing it.

DanKnowles - Posted - 01/17/2011:  18:21:18

String,
You're right I'm not I really am not happy with the slip...

Ron, Timothy & Karen,

Thanks for your comments. I do agree that it is a bit over the top!

DanKnowles - Posted - 01/17/2011:  19:05:40

MOOVIN', ON

I started out washing off quite a bit of the white junk and started off stickin' on the star shaped brackets. I want to get this 'un done!

Most of this post explains it's self so I won't write a whole lot.

Here are the bracket nuts, just out of their aging bath. My baths don't usually make me feel older, still somehow it does it to these other nuts!



Here the first of the star shaped bracket shoes is being mounted.







And another.







Ah... John Balch, this ones specially for you....

CS Memphis - Posted - 01/17/2011:  19:09:01

This is great - I am taking notes. One day...

jbalch - Posted - 01/18/2011:  06:02:01

Dan:

Glad you marked the banjo that way. But someday an unsuspecting collector out there still might see it and be convinced that you were a builder from the mid 1830s ... previously unknown .... (but quite prolific - it turns out). Obviously, this was your 112,010th banjo.

Steven M - Posted - 01/18/2011:  13:10:50

Getting close to sound files time!!!

DanKnowles - Posted - 01/19/2011:  16:58:13

John,
Do you think that David might be that first unsuspecting person!

Steven,

Not long now... Maybe video too!

DanKnowles - Posted - 01/19/2011:  18:38:48

HEAD TYME

Getting closer to sound fyles r we?

Yep.

In fact tonight the head goes on....

I'm using a nice thin variegated goat skin head that I baught from Bill Miller at Banjoscene. I believe that he advertises his heads (mounted and unmounted) here on the Hangout. They are around $15 and are a bargain and the quality is quite high. Bill's a real nice fella too!

Any way I wet the head for a short amount of time and then spread it over the top of the of the rim. Place the flesh hoop over the skin and then pull the excess up through the tension hoop.



Then J-hooks are installed....



and there it is. I usually let a new banjo head dry overnight before I trim away the excess.



HAVE Y'ALL SEEN JOHN BALCH'S ANGELINA BAKER VIDEO?
Here is a link for it. Check it out it is a nice one!

banjohangout.org/myhangout/vid...p?id=6916

Slingerland - Posted - 01/19/2011:  18:44:07

As always, it is looking old and used. Keep up the great work!

mojo_monk - Posted - 01/19/2011:  18:53:04

What about all of the rust on the tension hoop??? Seems like that'd be bad for the vellum...

Edited by - mojo_monk on 01/19/2011 18:53:32

DanKnowles - Posted - 01/20/2011:  17:28:41

Paul,
Thanks so much.

Sean,
I don't think it will really hurt the head because I have taken apart many old banjos which had intact ancient heads with rusted tension and flesh hoops. That said I will lightly oil the tension hoop before I do the final setup, mostly so the rust doesn't get on David's white pants!

DanKnowles - Posted - 01/20/2011:  18:53:03

PEG TYME

Now we come to the making of the remaining hardware, ie. the tuning pegs, tailpiece, nut and bridge.

My good friend Tommy Ogle (who is now home recuperating from his recent fun) did most of the turning of these pegs. Unfortunately his old buddy Dan forgot to get out the camera and shoot some photos so I can't show any of the turning. If you would like to see the turning go to my post Restoring 1850 and there are a whole bunch of photos of pegs being turned there.

These pegs were turned using some very old wood called Bodock, Hedge Apple or Osage Orange. This stuff is hard, man is it hard and tuff!

After those pegs were turned I still had a bit of shaping and sanding to go. The knob end gets most of the work. First it gets shoved into the roller end of the big belt sander.



After the mass of wood is removed it is put on the orbital barrel sander for a bit of fine finishing.





Here they are.



Now the hand work really begins. Each shaft has to be milled in the peg shaper. This thing works like an acoustic pencil sharpener shearing away wood until the shaft has the correct taper.



All shaped!



Next the tapered reamer is used to open and size each of the peg holes.



The pegs are checked again and again for fit.






All in and ready to recieve there string holes... next time.

BNJOMAKR - Posted - 01/21/2011:  05:22:00

They look like a small army, standing at attention, waiting for the next orders from their commander!

Jonnycake White - Posted - 01/21/2011:  09:24:10

Beautiful pegs. I really like looking at the different shapes for the peg knobs and the different little flourishes that builders come up with.

Steven M - Posted - 01/21/2011:  13:43:50

Love the colour contrast between the pegs and the neck

DanKnowles - Posted - 01/21/2011:  17:19:10

Marvin,
You are right, they do look like little wooden soldiers What a neat thought.

Jon,
Thanks. In the restoring 1850's Tom Bergan posted a photo of a whole bunch of different pegs... all neat, all unique.

Steven,
I apologize in advance as you will soon see.

DanKnowles - Posted - 01/21/2011:  17:43:07

PEGS & FITTINGS continued...

Today has been quite a day. I am working on bookings for a tour down to South Carolina. I'll be performing with the Southern Sons, a Civil War reenactment band, in Aiken (just a bit outside of Augusta, GA on Feb. 26. I will be available for house concerts, workshops and such in the Atlanta, Chatanooga Augusta aria Feb, 25 and 27.

Back at the pegs...

A piece of wood is used to determine peg height.



Cutting with the Japanese saw.



An awl is used to mark for drilling the string hole.



Drilling...



Before the pegs are stained they have their ends rounded, the whole peg is sanded to 1500 grit. I want them slick and Osage Orange can get slick! Here I am preparing to stain the pegs.



Staining.



Now the aging abuse begins with burnishing of the now stained peg handles.



Installed...

dbrooks - Posted - 01/21/2011:  17:56:39

Just stunning, Dan. The rim, neck, pegs, hardware all just looks like they belong together after having spent a century together.

David

DEmery - Posted - 01/21/2011:  18:00:43

Dan the pegs are really nice. I recall the initial bridge you made for Sherry Lynne (ebony banjo) out of this material. It has an interesting mustard color that should provide undertone to the stain. I am reminded again how thin the headstock is on the 1850. This banjo was made originally by eye I suppose but it does have delicate design. As always - I look forward to seeing the parts come together. David E.

Steven M - Posted - 01/21/2011:  23:54:23

I wasn't being facecious. I did actually like the yellow but now I see the dark brown is more appropriate.

DEmery - Posted - 01/22/2011:  06:13:38

Steven that yellow color is interesting but I agree it is more appropriate toned back in color...I think. My father use to buy knives from an ole' fellow named Josh Bane that used Bodock for handles. It is hard, durable, and should make a peg that will last another 150 years. David E.

rubicon - Posted - 01/22/2011:  12:21:22

really looks vintage Dan great job

DanKnowles - Posted - 01/23/2011:  09:06:09

David B, David E, Steven & Tim,

I really appreciate your comments, I too very much like the yellow of the bodock. After time and exposure it turns a very nice reddish brown. On some of the future 1850's I may leave the bodock alone... dependig on what each of their new owners desire.

DanKnowles - Posted - 01/23/2011:  09:25:19

TAILPIECE & BRIDGE

Again like the tuners, I got in a bit of a hurry and neglected to do photos of the cutting out, drilling, shaping and sanding of the tailpiece. I am sure sorry about that. Still if you wish to see more go over to RESTORING 1850 and there are lots of photos including the destruction and rebuilding of that tailpiece.

Here is the tailpiece in all its pristine bodock glory.



Stain tyme...



Now burnished...





There tiz...



So here I am starting to draw out the bridge. From measuring Using a straight edge over the head I know about what mu bridge height needs to be. So I draw a line indicating the top of the bridge on a fine old piece of spruce.



Then the rest of the bridge.



It is cut out on the band saw the shaped using a block plane ans a round file.

jbalch - Posted - 01/23/2011:  09:44:58

Dan: I think natural color bodock tuners and tailpiece would be very striking.

DanKnowles - Posted - 01/23/2011:  10:09:40

John,
I quite agree.

DanKnowles - Posted - 01/23/2011:  10:11:03

And it would age well and last at least as long or longer than most ebony.

Jonnycake White - Posted - 01/24/2011:  09:35:01

FWIW, I believe that "Bodock", or as it is sometimes spelled, "bodark",is derived from the French "Bois D'Arc" meaning bow-wood. My first encounter with this wood was a fellow at my local living history village who had bought a piece and was attempting to make a bow. I don't know if he ever finished it. But as far as I know it was used for bows by some of the plains tribes of Native Americans, where its other name, Osage, originates.

Speaking of history, one story I heard (and believe to be true) was that the pioneers coming west in covered wagons would bring bare root Osage saplings with them in case they needed to replace a spoke on a wagon wheel. The wood was flexible enough to bend to fit between the hub and the fello (wheel sector). Some times the saplings survived the journey and were planted and grew. There are areas in Salt Lake City at the mouth of Emigration Canyon where there are Osage orange trees still growing. Now that is one tough wood.

I once received some scraps and tried to make pegs out of them but unfortunately the scraps were too small and the grain too skewed, and I was not successful.

DanKnowles - Posted - 01/24/2011:  19:48:23

SHE'S DONE

Well at long last the reproduction 1850's Jacobs banjo is complete. So over the next few days I'll be posting photos, mp3 files and if I can get it done a couple videos of the banjo

So without further adieu, I present
the
NEW
1850'S JACOBS
BANJO











Jonathan Farrell checks her out for the first time.



Ron Allen gets a chance too.

Sutty70 - Posted - 01/24/2011:  20:00:56

Dan, being new to the hangout I have had the joy in being able to read both this and the 1850 restoration project without having to wait for the next interesting installment. Thanks for the great and very informative threads, you are a true craftsmen.

Stringbean45 - Posted - 01/24/2011:  20:15:58

Hey Dan,
Great job. Looks like it was just found in an old attic, in an old southern plantation.
And a big thank you, for not breaking the tailpiece.
Be looking forward to your next project.
Don