Slingerland - Posted - 11/26/2010:  15:13:11

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Wonderful, as always. I am grateful for all of your hard work and dedication to these threads.

DanKnowles - Posted - 11/26/2010:  18:24:47

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Tim & Marvin,
I'm glad to be back, I hope you enjoy the rest of the ride.

R F,
Yes Jon is right the bleaching is the first step in the aging process. The Original banjo (The Jacobs ca. 1850 that we restored here on BHO) had sun faded to a lighter color that the one which I would have had were not the wood bleached. You can look at the photos on Restoring 1850 or by going to the photos of that banjo on my home page.

John,
As I said above you are right as always. And thanks for the vote of confidence.

Slingerland,
Thanks to you too, as always!

Trisha S - Posted - 11/26/2010:  19:23:28

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Bleaching the wood prior to stain: Wild guess here... Besides lightening the wood uniformly, the bleach would also kill any microorganisms remnant in the wood as well as any left from handling. There's a limited amount of oil on a hand as well as acid. Was this a consideration?

DanKnowles - Posted - 11/26/2010:  19:27:03

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FINISH LINE 2

Well after all that wood bleach dried, I sanded with son fresh 600 grit sandpaper. The water in the bleach raised the fir (fuzz, whatever) and that stuff has to be cut off befor continuing.



The next job is burnishing the wood surface. This is done with a burnisher that my granddad made up for sharpening scrapers. This pushes and compresses the wood fibers helping seal the the wood, limiting the amount of finish which penetrates.







Next I stamp my name, date and serial number on the upper (unseen) side of the dowel stick.

DanKnowles - Posted - 11/26/2010:  19:32:36

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Trisha,
That is a very fascinating idea (microorganisms and all) and exactly what I was desiring to do, In all seriousness I never thought about that I only wanted to lighten the wood surface first.

DanKnowles - Posted - 11/28/2010:  15:25:18

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IS THIS DISTRESSING YET?

Before continuing on with the finishing of this Jacobs style neck I guess I should recap where we have been so far.

Completed so far...
1 Sanding.
2. Bleaching.
3. Sanding
4. Burnishing

Good I guess I know what I've done, sometimes a fella just get a bit lost... at least I do!

Well now we continue working on getting the wood to that nice aged appearance that we are looking for. Going over selected arias of the neck, which need darkening and pre-dirtying, I rub in some ground graphite. This is the stuff sold as a lock lubricant.



It gets thoroughly rubbed into the grain the again sanded with 600 grit.



Next I size the surface of the wood. This step is not usual for most banjo makers old or new, but it is being done to keep the finish from changing the wood color tone. Normally this technique is used by violin makers who wish the finish to lay more on the surface of the instrument and not penetrate much. Here I am sizing with thinned hot hide glue. It is just rubbed onto the surface.

DanKnowles - Posted - 11/29/2010:  18:32:41

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FEELIN' MUCH OLDER...

continuing....

Now that tonight's epistle is beginning...lord a mercy how do I get this thing a going? When I was in writing classes they always said start strong. How I wonder, do you start strong when one is talking about sanding? An offal lot of folks who work wood would rather not even think about sanding. But tonight I must start with sanding, specifically sanding with dead sharp 600 grit the hide glue size we put on in the last post.

Here tiz...the sanding. I'm just smoothing out any bumps and raised grain.





Then I begin burnishing again, polishing the surface.

By the way, here I'm working on a new little bench that I just made. It was built on the frame of an old hospital bed table. It has a small top which works wonderful for most of my work and is fully adjustable up and down.





Now I'm burnishing with a glass peanut butter jar. It works great!



Now at last we are ready for the first bit of finish to go on. I'm using French Polish, Spirit Varnish or whatever you wish to call it. It is basically shellac & alcohol with small amounts of other things like benzoin, copal and sanderick added. I mix it up and put it in this plastic jar. I apply these first coats with a small folded cotton cloth.





First coat complete.






to be continued...

XXXris - Posted - 11/29/2010:  19:20:48

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Thanks for keeping this up, we are all enjoying it. Please be nice to those banjo necks; I am afraid something is about to happen to them!

Steven M - Posted - 11/29/2010:  23:42:10

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Those necks are really coming on nicely. There is a warm glow coming from that wood.

BTW, who takes the photos, I am sure you have told us before but you must also offer them our thanks.

Jonnycake White - Posted - 11/30/2010:  13:33:56

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I sure have a lot to learn about finishing. This has been great.

BTW one of my favorite tools for burnishing is a piece of cow bone I had left over from making inlay blanks.

DanKnowles - Posted - 11/30/2010:  18:24:50

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Chris & Steven
Thanks Ido enjoy doing this. I shoot and process all the photos that you see here. I use a tripod and my camera has a delay, multi shot function. I've gotten pretty good at setting it up and hitting the buttons even as I work. It hardly slows me down anymore.

Jon,
I like that bone idea. Gives me an idea. Ah...Adam lost a rib...

DanKnowles - Posted - 11/30/2010:  18:31:35

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Chris,
I didn't complete my answer to you...
I apologize in advance for what I'm gonna post today!

DanKnowles - Posted - 11/30/2010:  18:54:42

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I GET DISTRESSED WHEN I THINK OF THIS #1


To do what I am about to endeavor to try requires a few things to do successfully Firstly the willingness to really look and examine the real thing. I had an art instructor in collage who said that he was there not to teach us to draw, but to teach us to see and then drawing would follow. This is true of distressing (aging) a piece too. What are the true colors, finishes and wear spots that we see? Why is the original like it is? What techniques did the makers use? Lastly how do I pull it off?

The hard part is finding the correct balance between too much or to little of any technique.

Anyway on to the work.

Again , as always, I start sanding. When in doubt sand!



I love this! Bring on the fire (but keep water ready). I'm using a propane torch.







First char!



Sanding and rubbing the charring in.



Hitting it with another coat of spirit varnish.





to be continued...

DEmery - Posted - 11/30/2010:  19:24:14

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Dan I went back to the original 1850 photos on your other thread and studied the variations in color and finish. It is always interesting to watch these steps unfold in your building and it is interesting to see the effect of charring compared to the original. I agree seeing what was on the original Jacobs is the trickiest first step to getting this project correct...right to drilling the peg holes in the incorrect, correct spots. Looking great. David E.

Tackhead - Posted - 12/01/2010:  05:54:26

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My God, you're brave with that torch

~John

Viper - Posted - 12/01/2010:  07:25:16

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In case anyone else wants to go back and look at the original 1850, here's the link: banjohangout.org/topic/180531

Great stuff as usual. Cheers!

DanKnowles - Posted - 12/01/2010:  18:06:11

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David,
I'm glad you caught that drilling pattern. That was a difficult one for me to do. Believe it or not I really wanted to make it symmetrical.

John,
Not brave just crazy.

Brad
I keep referring back to those photos as I am working on the banjo.

DanKnowles - Posted - 12/01/2010:  18:48:06

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DISTRESSING ISN'T IT ? #2

(continuing)

Of course the first step is....

SANDING.

Whoed a thunk it?

Sanding at this step smooths edges and smudges the charring into the unburnt grain.





Now burnishing...





Burnishing the peg head edges on the tile of my floor.




Here I had some fun, burnishing the edges (and rounding them) by rubbing it on the edge ob my workbench.



Now I'm preparing one of my favorite tools! Usingmy torch I burn & char the end of a paulonia scrap. This wood doesn't burn well but chars beautifully.







(to be continued....)

omiimii - Posted - 12/02/2010:  09:29:55

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sometimes i am amazed that your banjos can withstand the abuse you put them through!
i guess they know it's worth it in the end because they sure come out looking great.

DanKnowles - Posted - 12/03/2010:  19:28:16

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Allen,
Just think, The abuse" that I heep on these banjos is nothing but a compression of the abuse they receive over many lifetimes. I'm glad you approve of the outcome.

DanKnowles - Posted - 12/03/2010:  19:50:16

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7TH DISTRESSING

Is your memory as bad as mine?

Do you remember the last photo of the last post?

Well this is what I do with that stick of charred wood. Remember as you look at this, it ain't done till it's done.





Remember, I am replicating the coloration and marks of the original. Constantly I am referringhangoutstorage.com/banjohangou...22010.jpg back to the photos of the original Jacobs. As I do this I am keeping them up on my computer and I spend more time looking at them than actually doing the distressing.



This scratch is on the original. It looks like someone placed it there as a marker of some sort. So I follow their lead.






Using a heat gun I melt in some dark wax.







(to be continued...)

DEmery - Posted - 12/03/2010:  21:04:51

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Dan it has become an art class. I like it. David E.

trapdoor2 - Posted - 12/04/2010:  08:40:17

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LOL, when these hit the market, folks will be asking owners when they intend on restoring them!

DanKnowles - Posted - 12/05/2010:  07:43:16

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Marc,
Don't laugh...I've already been asked!!

DanKnowles - Posted - 12/05/2010:  08:42:37

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LEAF
by
NIGGLE

Each morning when I carry my grandsons to school I pass this pond. I've watched as it has changed through the seasons. Winter , Spring, Summer & Fall for the past 25 or so years. On this Friday I just happened to be hauling my camera so I stopped and tried to capture jut a bit of its loveliness.



I'm quite sure that you are getting tired of this neck destruction. So instead of continuing on the dispoilation (a new word for Sarah Palin {oddly enough my spell checker said that I mis-spelled poor Sarah's last name. When I checked for the correct spelling it gave me pollute... odd ... ) of this poor old banjo neck I figured we'd look at the work on the rime which is continuing on a similar path.

Now on to the banjo.

I will be trimming out the top or bearing edge of the Jacob's style rim. The rim is about 1/16" to taller than needs be. Here I'm marking all the way around the rim using my finger as a guide.



Here my jack plane is installed upside down in the vice, I'll be using it much like a un-powered joiner to trim the edge.







Shavings on the floor.



Here I'm using a small rounded bottom violin makers plane to ease the edges. On the original both inside and outside edges were eased so I will do the same. As a side note the outside or bearing edge must be eased or the head can ber ruined when it is tightened.





Ah yes David, this is...

Here is another photo of that same pond.



How did this sneak in?



(to be continued...)

CS Memphis - Posted - 12/05/2010:  08:52:42

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The bridge on your banjo in the bottom photo (the on that snuck in) sites right smack in the middle of the head. What scale did you use to achieve this? 11" or 12" rim?

Bluegrass-Gibbs - Posted - 12/05/2010:  09:07:06

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thanks so much for sharing your knowledge. It is all stunning and inspiring beyond words - true art - if threads could be heirlooms, this is one of them!

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Edited by - Bluegrass-Gibbs on 12/05/2010 09:35:17

DanKnowles - Posted - 12/05/2010:  09:33:46

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Christian,
That banjo has a 25" scale and a 12" rim.

Becca,
Thank you so much. Your kind words make the all work worth it!

DEmery - Posted - 12/05/2010:  09:48:12

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"David it is" your rim...and thanks. Glad to see the ebony banjo finally got all gathered up and tossed together. I look forward to your thoughts on how it settles in and matures sound wise. David E.

trapdoor2 - Posted - 12/05/2010:  11:16:44

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"LEAF by NIGGLE"

Tolkien always seems to sneak in, eh?

DanKnowles - Posted - 12/05/2010:  17:49:24

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David
You got it!

Marc,
You win a Tolkien to be redeemed on the P.A.R.T.

DanKnowles - Posted - 12/05/2010:  18:57:51

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OH BUT i AM SO DISTRESSED!

Tonight I am going to keep my comments to a minimum. Time is short!

Dark wax is being applied to the neck.



All this whacking has me distressed!





More charing...





Wax and the charring being melted into the marks.



Oh no...



More wax...



Now heat...



(to be continued...)

Slingerland - Posted - 12/05/2010:  19:40:05

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Very impressive, as always!

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Edited by - Slingerland on 12/05/2010 19:45:38

deuceswilde - Posted - 12/05/2010:  21:35:24

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Considering the era that this banjo would represent, would burnt cork not be appropriate?

DanKnowles - Posted - 12/06/2010:  18:02:28

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Slingerland,
Thanks, I'm glad you are enjoying it.

Joel,
What an interesting idea... maybe tomorrow.

DanKnowles - Posted - 12/06/2010:  18:27:19

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THE NEW BENCH

In an earlier post I mentioned about my new bench and I said that I would post a bit on it. Here it is.

Being as the bench is the heart of any instrument makers shop and as I have become enamored with this one, I figured I'd spend this whole post on it.

Here is wat I like about this bench.
1. It is small. I can' clutter it up with extraneous tolls and junk. It is just large enough for aguitar or banjo.
2. It is easily moved , anyplace in the shop. I can get to any aria of the bench.
3. It moves up and down quickly.

Downside of this bench is that it is not stable enough for heavy work. This is not something you wat to hammer a lot on.

Here it is in action. I realize this is a guitar not a banjo whose finish I am rubbing out. Still I hop it tells the tale.

BNJOMAKR - Posted - 12/06/2010:  19:39:16

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Dan
Your tabel looks like it might be an old hospital operating room bed side table.

DanKnowles - Posted - 12/07/2010:  18:16:50

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Marvin,
It is exactly that.

DanKnowles - Posted - 12/07/2010:  18:35:03

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I'M DISTRESSED ALL OVER AGAIN #9

Before I get too distressed tonight I've a bit of news. I'll be leaving for California tomorrow night so this may be my last post until I return next week... so please don't worry I'll be back!

You know this act by now, so I try and let the photos explain themselves... well sort of.



I've got some wax and char rubbed in the mess so now it gets cooked'



Waxing...



Cookin'











(too be continued...)

DEmery - Posted - 12/07/2010:  18:47:00

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Have a safe trip Dan. The neck is looking great and I look forward to seeing you after the trek west. David E.

DanKnowles - Posted - 12/14/2010:  18:38:10

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David,
Thank you, I'm glad I did!!!
The wedding was wonderful too!

DanKnowles - Posted - 12/14/2010:  19:25:45

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RETURN OF THE DISTRESSERZ #10



Oh Boy what a trip!

I left last Wednesday evening for a plane flight to California. All th while I was wishing it was steam powered. We went out for our youngest daughters wedding. I got in last night after many nights of long talks, picking and too little sleep.

But now I'm back and continuing with this distressing business.

Here is a photo of the original Jacobs banjo taken as I was taking it apart. Notice the notched aria on the dowel stick. I'm not sure what this was about but oh well...



Here I'm using a half round file to create this on the new neck.




Sanding...



Here it is...





Tomorrow I'll write about distressing the stick.

As always...

(To be continued...)

Bart McNeil - Posted - 12/15/2010:  15:41:34

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I am curious as to the wear pattern on the dowel stick... To what do you attribute the deep wear on the four edges of the stick in that particular postion? maybe I don't understand how the banjo was normally handled, or stored, or whatever... It just seems a rather unusual place for that significant a wear pattern.

A very informative series. I am just starting to build one based on an early fretless for my own use and willl be re-viewing your series often I am sure.

Bart McNeil

muleskinner63 - Posted - 12/15/2010:  16:14:02

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quote:

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Originally posted by DanKnowles

RETURN OF THE DISTRESSERZ #10



Oh Boy what a trip!

I left last Wednesday evening for a plane flight to California. All th while I was wishing it was steam powered. We went out for our youngest daughters wedding. I got in last night after many nights of long talks, picking and too little sleep.

But now I'm back and continuing with this distressing business.

Here is a photo of the original Jacobs banjo taken as I was taking it apart. Notice the notched aria on the dowel stick. I'm not sure what this was about but oh well...



Here I'm using a half round file to create this on the new neck.




Sanding...



Here it is...





Tomorrow I'll write about distressing the stick.

As always...

(To be continued...)

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muleskinner63 - Posted - 12/15/2010:  16:17:40

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Hi Dan glad and Mrs knowel`s had a safe trip. Hope i can make this Thursday to see you . I`am going to bring mattie she is sick OK? glad your back your friend Ron

DanKnowles - Posted - 12/15/2010:  19:18:42

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quote:

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I am curious as to the wear pattern on the dowel stick... To what do you attribute the deep wear on the four edges of the stick in that particular postion? maybe I don't understand how the banjo was normally handled, or stored, or whatever... It just seems a rather unusual place for that significant a wear pattern.

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Bart, I'd like to act like a very smart fella, but I have no idea why this wear is where it is at. I feel that at sometime in the original instruments life it was used as a stage prop... any ideas anybody?

Ron,
I always like seeing Mati May no matter how she is feeling.

SPLogDog - Posted - 12/15/2010:  20:04:16

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Maybe it's for a clip on resonator or a display?

drew-gurbach - Posted - 12/15/2010:  20:17:02

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Thats still the most amazing thing I've ever seen!

Stringbean45 - Posted - 12/15/2010:  21:19:48

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Hey Dan,
I've been following along on this project, as I have all of the other ones you have done, and really enjoying it. I do believe I'm beginning to understand a llittle of your "method of madness", making nice parts, and then beating them up, but I don't know if I can stand it, when you make the tailpieces for these banjos, and break them on purpose, to fix them. Please let me know when you are going to do this, so I can skip that session.
I undersatand you know what you are doing, and are very good at it, but it sure does hurt me, when you break someting so beautiful.
Don