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BNJOMAKR - Posted - 02/06/2012: 09:58:43
My foot is doing better. I'm walking with one crutch with toe touch only. I go for my first Dr. visit on Wednesday. I've been good at following his orders. I hope for a limited work release for next Monday. I have the stain applied to the mini banjo....
First, I sanded everything again with 320 grit sand paper, just for good measure! Then, I covered the outside of the resonator with paper and tape. I used wrapping paper because the back side has no ink on it. If newspaper is used, the ink will stain the wood. I made that mistake.... once! The inside of the resonator is sprayed with black lacquer, and left to dry overnight. The paper is then removed, and the black is scraped away from the top, outside edge of the resonator binding, leaving a white ring around the resonator. The binding on the neck and resonator was taped with vinyl tape to protect it from the stain. Alcohol mixed Vintage Amber stain was applied to the neck and resonator using an old cloth. The stain was applied to the neck carving using an artist brush to make sure all the nook and crannies were stained. Once dry, the vinyl tape was removed. The edges of the binding was sanded to remove any stain that had seeped under the tape, and to remove any tape adhesive that might be left behind. There was very little. The vinyl tape works much better than masking tape! The bottom outer edge of the resonator binding was scraped to remove any stain that was left on it. I used some 800 grit sand paper to light sand the neck and resonator, sanding slightly more in the center of the resonator to lighten the color more than the outside edges.
Dave1climber - Posted - 02/06/2012: 12:35:27
Marvin
It's good to know that you are making progress both with your foot and also your banjo build.
It doesn't appear that your foot has caused any problem with your finishing skills. Very good looking neck and resonator!
Dave
BNJOMAKR - Posted - 02/08/2012: 06:57:06
Yesterday, I mailed the metal parts to Precision Plating. They were packed in a flat rate box. The parts are not real heavy, but I had to use the large 12x12 box for the flange to fit. I added insurance and delivery conformation. The postal worker said that the total would be $21, then said, "Opps, that's a flat rate box... I need to refigure that". He did, and the total was $31! If I knew that it would have been that much cheaper, I would have found a cardboard box!
Edited by - BNJOMAKR on 02/08/2012 06:58:11
Dave1climber - Posted - 02/08/2012: 15:48:28
Live and learn! 
rubicon - Posted - 02/09/2012: 11:48:53
This is incredible have you ever made a full size banjo ?
BNJOMAKR - Posted - 02/09/2012: 13:47:17
Yes, here a couple that are mine. The pot assemblies are Stewart McDonald. The arch top pot is from the early 80's and the flat top pot is a 2006. The arch top engraved parts came from Stew-Mac, but I did the engraving on the ftat top. I built both banjos within the last 10 years. I built the arch top, "The Lydia Mae", in memory of my mom, and played it for several years until I built the flat top, "The Hollywood".
Thanks!
Dave1climber - Posted - 02/09/2012: 15:22:09
Very nice work!!!!!
Where are they now?
blindsniper - Posted - 02/09/2012: 22:25:15
Marvin. Your work is inspiring. Well done
BNJOMAKR - Posted - 02/10/2012: 05:14:47
quote:
Originally posted by Dave1climber
Very nice work!!!!!
Where are they now?
They are laying in here in their cases by an 1800's pump organ left to me by my mom.
JLB - Posted - 02/10/2012: 12:38:59
Just wow!! And the photos are as stunning as the instruments. Are you responsible for the photography as well?
BNJOMAKR - Posted - 02/10/2012: 16:00:44
Yes... I did the photos.
BNJOMAKR - Posted - 02/14/2012: 14:31:41
quote:
Originally posted by BNJOMAKR
Yesterday, I mailed the metal parts to Precision Plating. They were packed in a flat rate box. The parts are not real heavy, but I had to use the large 12x12 box for the flange to fit. I added insurance and delivery conformation. The postal worker said that the total would be $21, then said, "Opps, that's a flat rate box... I need to refigure that". He did, and the total was $31! If I knew that it would have been that much cheaper, I would have found a cardboard box!
I just got a call from Perfection Plating.... My parts are ready.... WOW, was that quick or what!!!! They received them at 9:32 last Friday morning, and they are already for shipment. I can't wait till they arrive! I've been putting the finish on the wood parts for the past few weeks. I'm going to have the metal parts back before the finish is done!
ken61 - Posted - 02/17/2012: 10:16:28
MArvin
I am super impressed ! Your range of talent is just terrific.
The marquetry, the inlay, the carving, the woodworking in general, the woodturning, the engraving, the finishing are all top shelf. You are a man of all trades.
Thanks for the pics ! Oh! the photography also!
ken
BNJOMAKR - Posted - 02/17/2012: 18:23:25
Thanks Ken!
My parts came in today, so I had a busy evening. I assembled the mini, made a string nut from pearl, put the strings on it, and adjusted the action . It came out nice! It has a really nice ring to it. It has been together now about an hour. I haven't taken any pictures yet, maybe tomorrow. I'm going to the Neuse River Music Festival tomorrow, in Kinston, and I plan to take it with me. I'll be starting on the case next week!
BNJOMAKR - Posted - 02/18/2012: 06:42:18
Here are a couple of pictures of the assembled pot. I "refurbished" the head by cleaning it and recoating it with a light dusting. I also painted the rim of the head gold to some what match the gold plating, so that it would not stick out like a sore thumb.
Edited by - BNJOMAKR on 02/18/2012 06:43:03
Dave1climber - Posted - 02/18/2012: 08:22:52
Marvin
I find that I am at a complete loss to find mer words to use. A totally inadequate WONDERFUL!!! 
Dave
BNJOMAKR - Posted - 02/22/2012: 18:38:49
I have the case started.... I sawed out the top and bottom and the side ribs of the case from Aspen shelving board that I bought at Lowes. The lid is made by gluing two ribs to the top. The main body of the case is made by gluing up four ribs to the bottom. The ribs are held in place while gluing by drilling holes for finish nails and inserting them between the rib layers as shown in the diagram. The nails keep the ribs from wondering around when the glue and clamps are applied.
yopasjim - Posted - 02/23/2012: 07:10:51
First of all, I am thoroughly IMPRESSED with your skills. I have adequate wood working skills....but you my friend are a MASTER woodworker! (And I am sure I am not the first to say that!)
Secondly, that is a BEAUTIFUL banjo! What a keepsake to pass down from generation to generation! WOW!
Thirdly, THANK YOU for documenting your progress. I believe this is worth of further documentation...such as a book. I would buy it in a heart beat!
This has been fun watching your progress. I am truly grateful you have included us in the journey! Blessing on you!
Dave1climber - Posted - 02/23/2012: 08:04:25
quote:
Originally posted by yopasjim
First of all, I am thoroughly IMPRESSED with your skills. I have adequate wood working skills....but you my friend are a MASTER woodworker! (And I am sure I am not the first to say that!)
Secondly, that is a BEAUTIFUL banjo! What a keepsake to pass down from generation to generation! WOW!
Thirdly, THANK YOU for documenting your progress. I believe this is worth of further documentation...such as a book. I would buy it in a heart beat!
This has been fun watching your progress. I am truly grateful you have included us in the journey! Blessing on you!
I could not say it any better. Keep up the flow of information. Take care of your foot.
Dave
BNJOMAKR - Posted - 02/23/2012: 17:03:34
Thanks, but I'm just a learn by doing crumudgeon... I hate it when I hear someone say, "I can't do that." I usually ask, "Have you tried?" My motto is "Those who never try... never will!"
It got up into the 70's today... beautiful weather! When I got home today, I took the dog for her walk, then when I got back, I started sanding the outside of the case. I was just about finished sanding when my wife came home early from work. She popped her head inside the shop and said, "Why don't you stop what you're doing and get out one of the trucks. I'll buy supper if you will drive. It's such a beautiful day, and I think we need to get the truck out and drive." I just couldn't pass up that offer! I backed out the '65 Chevy, pumped up the tires, loaded up momma, and went out on a date! I'll post pictures later... of the case, that is!!!
Paulf - Posted - 02/23/2012: 17:10:47
Hi, this has been a great thread and I too like others are amazed at your work. Looking forward to more.
Paul
yopasjim - Posted - 02/24/2012: 06:54:38
Just to clarify my statement....I am a woodworker and the more I see posts like yours the more confidence I am gaining to someday give it a try.
Like I said.....I would love to see the documentation of your banjo making in book form.
Thanks again for sharing....and I am glad you had a date night
BNJOMAKR - Posted - 02/24/2012: 14:31:11
This evening, I finished sanding the outside and inside of the case. The outside edges were rounded on the router table.
ken61 - Posted - 02/26/2012: 14:29:23
MY Friend:
Why do I spend $80 on a store bought case when I could make a very unique case like you have done ?
This is the way to go. Again, thank you for a really neat idea.
There is great opportunity to be original in the making of a case.
Thanks for sharing. It is posts like these that give new builders the courage to try . And what benefits there are in trying--and what enjoyment.
thank you!
Kermit thanks you also!
Edited by - ken61 on 02/26/2012 14:30:31
BNJOMAKR - Posted - 02/26/2012: 17:39:52
Ken
You can buy a case a whole lot cheaper than you can build one, at least the way that I build them! Also, the wooden case is quiet a lot heavier than the bought ones. A full sized wooden case would add a lot of weight to the total to be carried with a, mastertone style, resonator banjo in it. I build a case for my mini banjos because I can't buy one that will fit them.... and also it makes them a little more unique! In a black mini case, I have well over $140 in just materials, and many hours of labor. A veneered case involves more materials , and many more hours of labor in building, and finishing.
Marvin
BNJOMAKR - Posted - 03/03/2012: 14:14:36
I have the case complete as of this morning. I didn't take a lot of pictures of the construction because it is constructed in the same manner as the last case that I built for the Mike Scott mini banjo. The inside and outside of the case was sprayed with sealer and then sanded. The inside edges of the case were painted black. The outside of the case was then sprayed with automotive truck bed liner. Two neck support pieces were cut from 1/2" plywood and glued inside the bottom of the case. The interior is made from 1/4" black foam pipe insulation which is covered with crushed red cloth upholstery material. It is glued to the foam with 3M 77 spray glue, and installed in the case with Liquid Nails adhesive. The handle brackets are made from two links of chrome plated chain that are cut, drilled, and tapped for 4-40 screws. Two stainless steel pieces were made for the back of the handle brackets. The hinges, latches, and handle brackets are installed on the case. Holes for the "Walker" emblem is drilled in the side of the case lid using the clear plastic pattern that was made earlier. The emblem is installed on the case. Rubber feet are installed on the bottom of the case and on the back of the case near the hinges. A safety chain is installed inside the small end of the case to help guard against the case top being forced open too far. I'm overestimating 30 to 40 hours in the construction of the case! Below are the pictures I did take of the construction of this case, and some pictures of the Larry Barnes veneered case which shows the construction of the handle brackets, installation the rubber feet, and of the "Walker" emblem. I will post some completed pictures of this case and banjo soon....
BNJOMAKR - Posted - 03/03/2012: 15:51:43
I just noticed the word "overestimating" in the post above. It should be "guess-t-mating" . I let spell check change it for me. I definitely didn't "overestimate"... if anything I under "guess-t-mated"!!!!
Dave1climber - Posted - 03/04/2012: 05:44:06
I guess t mate all the time, and in this case I guess t mate that that however much time you put into building the case, they were well spent hours, what I see is very nice. Well done!!!!!
BNJOMAKR - Posted - 03/04/2012: 06:52:00
Thanks! I want to take pictures outside in natural light so that the colors will be true, but it has been raining here for the past couple of days. Maybe it will clear off soon!
BNJOMAKR - Posted - 03/05/2012: 06:32:16
I have to work a late shift today and was at home this morning. It stopped raining last night, and it's the sky is overcast today which makes for perfect lighting with no shadows. I took advantage of the conditions and took some pictures of the banjo and case. I'll try to take a video in the next few days. This mini banjo was built for Mr. Mickey Zacharias of International Graphics Group in Kansas City. I will be shipping out in a week or two!
bkdraft - Posted - 03/05/2012: 07:15:31
Just awesome! What more can be said.
ki4rex - Posted - 03/05/2012: 08:15:34
bkdraft,
You said it, there is nothing else to say.
stymie - Posted - 03/05/2012: 08:35:48
how's it sound?
b
Paulf - Posted - 03/05/2012: 12:58:43
I am so impressed with your work. That looks amazing. Great pics as well.
Paul
Dave1climber - Posted - 03/06/2012: 06:26:11
Marvin
I have seen a number of very nice banjos, your mini will stand with the best.
blindsniper - Posted - 03/06/2012: 23:55:47
quote:
Originally posted by BNJOMAKR
I have to work a late shift today and was at home this morning. It stopped raining last night, and it's the sky is overcast today which makes for perfect lighting with no shadows. I took advantage of the conditions and took some pictures of the banjo and case. I'll try to take a video in the next few days. This mini banjo was built for Mr. Mickey Zacharias of International Graphics Group in Kansas City. I will be shipping out in a week or two!
I like the banjo as well as the chair.
skollie - Posted - 03/07/2012: 09:50:15
great looking whats the sound like
frihauf - Posted - 03/07/2012: 11:48:07
Amazing!!!!
Ben
BNJOMAKR - Posted - 03/07/2012: 17:10:07
I finally made some videos of the mini banjo this evening. Here they are!
Paulf - Posted - 03/07/2012: 18:30:02
Great vids and does that mini look great. Amazing gloss on the back of the resonator and the pattern looks brilliant. Well done.
Paul
BNJOMAKR - Posted - 03/10/2012: 07:22:08
Thanks to all for the nice comments! I will be boxing it up and shipping it Monday or Tuesday. I have this really thick walled, oversized, cardboard box that has a lot of thick padding that I use. So far, I have shipped three banjos in it. The recipients have been nice enough to ship the box back to me each time. It has been to Indiana, Maine, Tennessee, and now will be going to Missouri. That box has traveled more than I ever will! 
BNJOMAKR - Posted - 03/11/2012: 13:55:54
I took some final pictures before boxing up the Zacharias mini banjo. It was a beautiful day here today!!!
Dave1climber - Posted - 03/11/2012: 15:46:23
Marvin
Many have posted photos of very nice banjos here on this site. If I had to pick the best of the best I would have a very difficult time of it. Yours would be amongst the top few. Heres hoping that you will start another build and take us along for the ride.
Cheers and take care of the foot
Dave
Evan C - Posted - 03/11/2012: 23:47:39
What a beautiful instrument, and it sounds as good as it looks.
Congratulations on finishing the build, and thanks for sharing.
BNJOMAKR - Posted - 03/15/2012: 02:51:09
The banjo arrived in Kansas City yesterday, and now has a new master! I always get a little emotional when I send one off.... This may sound corny, but It's sorta like sending one of your children away that you know that you will never see again.
BNJOMAKR - Posted - 05/29/2012: 02:51:14
quote:
Originally posted by Dave1climber
Marvin
Many have posted photos of very nice banjos here on this site. If I had to pick the best of the best I would have a very difficult time of it. Yours would be amongst the top few. Heres hoping that you will start another build and take us along for the ride.
Cheers and take care of the foot
Dave
Dave
I'm building a mini banjo for J.S. in Virginia. He is having it built to commemorate the birth of his first child, Carly Jane. I've been working on it for several months and will post pictures when it becomes more complete.
After buying four pair of shoes, I finally have a shoe that doesn't hurt my foot. I still have to wear a reworked Dr. Shoals insert in it. I just can't seem to keep that screw head from rubbing some part of the shoe.
Marvin
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