Dan Knowles - Posted - 12/08/2012:  19:53:36

Yesterday I had a great conversation with my good friend David Emery. Besides talking of banjo (which we always do), friends, and business we talked about this wonderful place called The Banjo Hangout. I the process he suggested the idea for this new forum... A LUTHIERS LIFE. 

Have you ever wondered about the working life of a full time Banjo/ Guitar builder repairman, Musician and artist? Well if you have then this forum will be for you. I'm going to attempt to follow my days with photos, words, recordings and perhaps an occasional video. Please feel free to comment and ask questions.... who knows where that will lead!

Anyway here goes todays post 12-8-2012...

Today being Saturday I got into the shop around 8 AM and began one of my most important rituals of the day, choosing the soundtrack for the day. Today I chose a true masterwork, John Balch's CARRY ON JOHN. If you haven't heard it, do yourself a favor, get a copy, in my book it is the finest clawhammer banjo recording ever made. 

In a short while my luthire students began to arrive. On Saturday mornings I teach BANJO and Guitar building. We go from 8:30 to around 1 PM. It is one of the more rewarding times of my week, being able to help these folks create their own instruments. Most who come to me have no or very little woodworking experience and so it is exciting to be able to watch them learn and become true crafts people. 

Here is my grandson Chandan's electric guitar body, preparing to glue on the back.

After the class ended at 1PM I walked home (I live 5 blocks from my shop) and got some lunch, took a short nap and went back to work.

I've a couple of projects I'd like to accomplish this afternoon. The first is gluing up a banjo neck blank. This will be another 'Art" banjo, called Voyager,  I'm building it for my pal Will Turner. It's wonderful how the folks I am privileged to work for seam to turn into friends. First I cut out a piece of ebony for a center filet, then thickness sanded it  and glued the sucker up. Monday I'll remove the clamps and perhaps true the blank up. I usually set the blank aside to cure for several months before work it.

Next I have a guitar neck repair. This old Alverez has a slightly cracked neck. Unfortunately it has been left unrepaired for a long long time and the wood has moved. I won't be able to completely hide this one. I glue and clamp it up to cure.

Next I get to work on the project I've been wanting to start for days. This instrument I'll be building will be a completely new animal. A wooden topped instrument that will be somewhat similar to August Pollmann's 1890's mandoline-banjo or similar to Wayne Rogers' Gold Tone BANJOLA, the main difference is that this will be a d"Amore... What you ask makes it a d'Amore? 10 strings, 5 regular fretted strings and 5 sympathetic strings, very much on the idea of Orpheus the Banjo d'Amore which I built for my pal Tom Bergan. By the way Tom is again helping me design this project.

So today I plan to (hopefully) layout and make the patterns for the body and neck.

First I laid out the patterns on masonite or hardboard. I like the stuff for this usage as it will stand up to the machining operations I have planned. It is some used blackboard material I salvaged from a local school remodel.

Now to the band saw to cut it out...

Truing it on the sander...

And now the completed patterns.

It is several hours later and I return to work on the Alverez's neck. Here I'm removing the clamps...

And sanding the neck true...

Lastly I go in the office aria and prepare this post.

Yep that's me at the computer.

It's now 7:30 and time to head home. See y'all later!

banjo.A - Posted - 12/08/2012:  21:17:24

That was a really nice/cool post and I enjoyed it very much, and the fact that you took the time and energy to post it is awesome too. You have my respect and I'm sure many others on the hangout as well. Thanks Adam...

russtul - Posted - 12/08/2012:  21:46:12

Many thanks for sharing your day

ellabrow - Posted - 12/08/2012:  21:48:38

GREAT POST!! Thanks so much for sharing and taking the time to document it all up for us. Really appreciated!

Elliot

Pick1949 - Posted - 12/09/2012:  00:08:32

I really encourage you to keep this up! I will read it if nobody else does! Always interesting to see what a luthier sees from day to day, from damaged instruments repair and poorly modified/adjusted sorts, to seeing some kinds of rare instruments at times too! I love it!

DEmery - Posted - 12/09/2012:  03:42:32

Dan good morning. I have only been in your shop a couple of times (actually once when I picked up the ebony banjo) but with our chats over the years it almost seems I have lived in Paris, Tennessee. I envy your ability to take a stroll home and nap during lunch. I plan to visit you in April and look forward to seeing the historic home you are restoring. For anybody that may not know Dan well...they will find your posts informative. I hope you do show tricks of the trade and your latest builds. There seems to be an endless interest by BHO members about what is being built, how it is done, and tips, etc..

For those that haven't had the opportunity to play a Dan Knowles banjo or see yous work..., let me attach a few images of your work. I use them often. I look forward to seeing you on BHO more often even with your busy day in the shop. David E.

Dan Knowles Applies French Polish to Ebony Rim

Knowles Projects

Knowles Jos

1975 F5 Gibson Master Model rebuilt by Dan Knowles

1975 F5 Gibson Master Model rebuilt by Dan Knowles

Ole' Abe built by Dan Knowles

Ole' Abe built by Dan Knowles

Ole' Abe built by Dan Knowles

1922 Vega S

1922 Vega S

1922 Vega S with Dan Knowles Neck built 2004

Ebony banjo Sherry Lynne built by Dan Knowles

Ebony banjo Sherry Lynne built by Dan Knowles

Ebony banjo Sherry Lynne built by Dan Knowles

Ebony banjo Sherry Lynne built by Dan Knowles

New 1850 Jacobs by Dan Knowles, Luthier

New 1850 Jacobs back by Luthier Dan Knowles

New1850 Rim

Goshen By Dan Knowles

Carved Scoop - Goshen by Dan Knowles

Goshen by Dan Knowles

Carved Bone Tuners

Rough Carving Goshen

 

Charley - Posted - 12/09/2012:  03:53:57

It sounds like you've got things pretty well figured out in life Dan.

Most of the banjo builds I've seen around the site aren't from outright luthiers. How long does the average build take for someone with your kind of experience?

Richard Brown - Posted - 12/09/2012:  06:18:30

Nice work Dan, thanks for taking the time to share your day!

Dan Knowles - Posted - 12/09/2012:  06:32:08

Banjo.A,  Tom, Elliot, Pick, David & Charlie,

Thank you so much for your interest, kind comments and David all of those photos... I sometimes forget about all of the Knowles pieces that you have. It will be fun to post your April visit!

Charlie, So much of the time factor in my building is the complexity of the project (and most are quite complex anymore). I know that I should have a good answer to your question... but I don't. If you follow the timeline of the Voyager or the d'Amore you might have a better I idea than me. The Ebony banjo (look in my photos) which I built here on the BHO took around 9 months.

Dan Knowles - Posted - 12/09/2012:  06:35:15

Thanks Richard.

I really like that last banjo you posted, as always it is great work. That heel inlay is outstanding!

Dan Pennington - Posted - 12/09/2012:  07:07:44

Dan, you really know how to make a luthier's life look glamorous!  You must be fighting off the groupies every time you go outside.  I know I do. This little old lady down the block waves at me every time I drive by.  Pretty wild, huh?

Dan, another luthier.

banjered - Posted - 12/09/2012:  07:27:15

Vury KOOL posts! Banjered

DEmery - Posted - 12/09/2012:  07:32:59

Dan your forgot about all the pieces on my wall from your shop? My bank hasn't forgotten but it has been more than worth it. David E.

Tim Purcell - Posted - 12/09/2012:  08:47:11

Great photos and a nice walk through of a day in the life of a luthier, Dan.

Do you cut out most of your neck blanks that way? That just makes since to me. What is the point of making a huge block, drawing out the template, and then bandsawing that thick piece to remove the excess. I like your method. I may try that on my next neck. Thanks for sharing, Dan.

Tim

Paul Meredith - Posted - 12/09/2012:  10:17:29

Dan, thanks for sharing, great thread.  I have seen Orpheus and it is a delight, I hope your latest project is similarly successful.  Certainly you'll get a lot valuable input from Tom.  DE - very interesting pix.

Dan Knowles - Posted - 12/09/2012:  10:33:57

Tim,

In answer to your question, Yes I nearly always do multi piece necks. They are stronger and more stable. Gibson guitar necks from the early Nashville years are a true case in point. I've seen and tried ( and been successful on occasion) to remove twists and bows caused by single piece incorrectly cured wood. Seldom will I see old Vega  (built like this) necks with twists. Occasionally there will be bows (due in part to lack of truss rods and steel strings) but seldom twists.

Dan Knowles - Posted - 12/09/2012:  10:40:11

Paul,

I thoroughly enjoyed building Orpheus and working with Tom Bergan. In fact I'm thoroughly enjoying working on this new d'Amore instrument.

Tom Berghan - Posted - 12/09/2012:  12:47:24

Here are photos of my custom Dan Knowles banjo:banjohangout.org/myhangout/pho...umid=6237

Unquestionably the most noble banjo ever made in all history (I am somewhat biased of course).  Well, you can judge for yourself!

One thing that Dan probably won't mention - he is also a great family man (husband, father, provider, and fix it guy!)

Best Wishes my good friend!  Tom

Ken LeVan - Posted - 12/09/2012:  13:11:10

Very nice! Great thread.

Dan's a man after my own heart, making all kinds of instruments, and inventing things as he goes - his shop is full of interesting stuff which shows his versatility.

It's such a pleasure and reassurance to me to know that there are people out there making banjos that aren't copies of Gibson Mastertones, and equally importantly, that there are people commissioning them.  There are some really good builders and designers on the Hangout.  Makes me happy.

Years from now (I trust) the custom one-off hand made banjos will be the ones that endure as pieces of the Luthier's art, and fake Mastertones will be- well, fake Mastertones.

dbrooks - Posted - 12/09/2012:  13:42:27

It's great to see you back on the Hangout and sharing your art and wisdom with us.  I'll be checking for updates from you often.

David

Mike Casey - Posted - 12/09/2012:  13:43:01

Thanks Dan. I appreciate your taking the time to let us in your shop. I always enjoy your posts and seeing your work. Where might one get the Balch recording?

Dan Knowles - Posted - 12/09/2012:  14:30:47

Tom....gosh....

Ken, thanks a bunch for your comments... you have sure posted some nice work lately! Ya know it's funny, my banjo making career started back in the 70's (1970's not 18) and it was ... aah...cough- cough ... building Mastercloanes. I learned the art of cutting pearl doing Hearts & Flowers, Flying Eagle and Wreath patterns. I'm so glad CNC's have taken over cutting those things.  Even then I did love the open back banjos (I owned Farland, Vega, Stewart, Cubley and even a Supertone) and I loved those old unwanted redheaded stepchildren of the banjo world. And so I was privileged to work on some of the best back in the day when they could be purchased for little of nothing and a beginner would be trusted with Grandpas old Fairbanks. I do hope that some of my work survives. But I also realize that greater works than mine haven't. I guess my favorite story dealing with this is Tolkien's short story  "Leaf By Niggle."

Thanks David, it's always great to see good  friends here on the BHO. I still play your sisters "Angel of Mercy" CD, what a nice recording!

Mike thanks.  You can find John's music here

johnbalchmusic.com/  I hope you enjoy it at least half as much as I do.

Edited by - Dan Knowles on 12/09/2012 14:33:17

Ken LeVan - Posted - 12/09/2012:  15:17:06

quote:

---

Originally posted by DanKnowles

Tom....gosh....

Ken, thanks a bunch for your comments... you have sure posted some nice work lately! Ya know it's funny, my banjo making career started back in the 70's (1970's not 18) and it was ... aah...cough- cough ... building Mastercloanes. I learned the art of cutting pearl doing Hearts & Flowers, Flying Eagle and Wreath patterns. I'm so glad CNC's have taken over cutting those things.  Even then I did love the open back banjos (I owned Farland, Vega, Stewart, Cubley and even a Supertone) and I loved those old unwanted redheaded stepchildren of the banjo world. And so I was privileged to work on some of the best back in the day when they could be purchased for little of nothing and a beginner would be trusted with Grandpas old Fairbanks. I do hope that some of my work survives. But I also realize that greater works than mine haven't. I guess my favorite story dealing with this is Tolkien's short story  "Leaf By Niggle."

 

Thanks David, it's always great to see good  friends here on the BHO. I still play your sisters "Angel of Mercy" CD, what a nice recording!

Mike thanks.  You can find John's music here

johnbalchmusic.com/  I hope you enjoy it at least half as much as I do.

 

---

We all learned how to do it that way - I started in the 60s and we all wanted to learn all about Mastertones - they weren't all that old.  My industrial design thesis at Pratt was an acoustical guitar, and back then I hung out with John D'Angelico and William Del Plilar.  A different era, a different point in time - information was passed on by an oral tradition. I had to learn about guitar construction by visiting the Martin factory in Nazareth PA numerous times, and researching violin construction in the NY public library. Now it's all "out there" for those who choose to look.

vdiazleroy - Posted - 12/09/2012:  15:28:21

Thank you for sharing. And, what beautiful work!

Kaelri - Posted - 12/09/2012:  16:54:27

I am so glad you took the time to post this thread. I find this stuff so interesting to read as I am fascinated by how banjos (And many other stringed instruments) function and how they go together....etc......

BNJOMAKR - Posted - 12/09/2012:  17:09:44

Dan, it's nice to have you back posting on the hangout... and this will be a great adventure!

Edited by - BNJOMAKR on 12/09/2012 17:10:23

Ho C Ying - Posted - 12/09/2012:  19:55:19

Dan, glad to have you back! Very cool post!

Weitzel - Posted - 12/09/2012:  22:54:38

I am so grateful for the openness that so many luthiers, like Dan, show on this site. I am an aspiring luthier working on my first banjo prototype and this stuff is invaluable. When I started making a few archtop guitars in the mid-90's, although that wasn't that long ago and the internet was already around (although I used it very little at the time), it seemed that most all luthiers were very closed to sharing the information they worked so hard to gain. Now I just do a quick search and find information on whatever I need. I haven't built guitars in a while, so I'm sure there is a host of information for them out there now, too, but it seems that overall, banjo people are just friendlier and more open. Yet another reason to like the banjo. If there is anyone my age (40) or younger reading this, I hope you don't take this kind of information for granted!
Thanks!
Jeff

jbalch - Posted - 12/10/2012:  05:10:44

It is nearly Christmas ... Time for things like the classic Jimmy Stewart movie "Its a Wonderful Life."

The premise of this thread made we reflect on what it would be like without folks like Dan Knowles who build the things we all enjoy so much ... pretty bleak I'd say. 

BTW Dan - THANKS for the comments re: my music.  It means SO MUCH coming from an awesome artist and performer like you

Dan Knowles - Posted - 12/10/2012:  06:11:03

Valerie, Ellen,

I'm glad to be here and am surprised at the interest folks show in how my days go!

Marvin, I sure hope so!

C Ying, It's good to be back... it's even better to have friend from China! When I was young I'd have never imagined.

Jeff, I guess I was quite fortunate back when I got started. There were folks who were interested in me and took the time to show me some of the ropes. I am thankful to these folks and I am here because of them. So I guess this is a formal thank you to; Don McCarty, Chuck Erickson, Frank Ford and the Guild of American Luthiers.

John, How did you know that IT'S A WONDERFUL LIFE is my personal favorite movie?

jswkingsfield - Posted - 12/10/2012:  09:31:18

Good to see you, Dan!

Kaelri - Posted - 12/10/2012:  17:18:51

Dan, yes, I am very interested in learning about the building of musical instruments. I am considering taking an entry level sort of course from a gentleman who used to work for Gibson in Kalamazoo. In fact, I spoke with him about 2 weeks ago in regards to taking his course next year. I've seen some of his work and it is simply beautiful.

Ellen

Dan Knowles - Posted - 12/10/2012:  18:28:50

Janice, Thanks for lookin' in!

Good luck with that Ellen. I do hope it works out well for you.

Dan Knowles - Posted - 12/10/2012:  19:58:07

10 December 2012

I stepped out on my front porch this morning and realized immediately that I had left my bicycle at the shop Saturday. Oh well, I guess I'll walk in. Other than that it is overcast and a bit chilly this will be a perfect morning for walking and shooting some pictures. So I pulled my trusty Easy Share camera from its pouch and began shooting. In fact I took picture after picture on my walk. Here are just a few...

Our 112 year old home... 

The pre Civil War plantation house across from us...

A derelict Victorian that could be sooooooo cool if some one had some money and cared. It has 12 foot ceilings and some of the most beautiful moldings I have ever seen in a private home.

Paris is the county seat for Henry County in Tennessee and has one of the prettiest courthouses around.

The First Baptist Church is right across the street from my shop...

Here in all its sideways glory, the place where I work....Knowles String Instruments....

So on to the day. I've a whole lot I want to accomplish before the afternoon is filled with folks who want to learn to play banjo & guitar. First I need to finish up prepping the patterns I started the other day. This includes marking pertinent  information on them. Then drilling hanger holes on them and then hanging them up.

Next I popped the clamps from the neck blank I glued the other day. The photo doesn't show it but the maple on this one is quite figured and very nicely matched.

This one will take a while, I'm refurbishing a lap steel built by my friend Tommy Ogle (you've seen here on the Hangout), It has some electrical problems and needs cleaning, strings and a new cover plate for the electronics. You might want to note the phone sitting on the bench. This is its position most of the time while I'm working. I keep it on speaker phone and keep my hands busy. It's too bad I didn't catch a photo of me laughing. Retired banjo/ mandolin luthier Tom Morgan was on the phone and cram full of great stories!

As I was working on the little guitar in walks my buddy Gary Jinkins, he needed a trussrod adjustment on the guitar that I built for him. Of course this necessitated a bit of pickin'...ah... just an inspection, don't ya know.

It is a neat little double ought size guitar... I shot some photos and post them sometime soon.

Then it was back to work sanding the cover plate I  had created from tortoise shell plastic and Plexiglas. Then buffing it to give a baby's butt competition!

Soon my first student of the day arrived, Debbie Reagan with her Knowles banjo "Sweet-Thang".  Yes I'll post some photos soon of this one too.

 And so it went, teaching, going to a R. E. Lee Acadamy for the Arts board meeting, talking to clients and teaching somemore until 7:30 tonight when I headed home to write this post.

See y'all tomorrow!

DEmery - Posted - 12/11/2012:  01:50:50

Dan I think Paris is a truly pretty little town. I hope to see that old home when we get together in April next year. David E.

Jonnycake White - Posted - 12/11/2012:  09:32:26

Dan - I'm happy to see you posting again, your work is always an inspiration. One of these days I'll have to take a banjo pilgrimage to such places as Tennessee, Pennsylvania, Illinois, and Arizona.

tommy4227 - Posted - 12/11/2012:  12:59:09

I'm a former student of Dan's. My education from him was short-lived, but I have to say this guy is very gifted.

Dan, I love your work. I wish I was still living in the area and could attend your classes. I have a lot to learn, and you have a lot to teach. Building my own guitar has been a dream of mine for some time. Too bad I had to miss out on this opportunity. Learning from a master craftsman and musician such as yourself would be awesome.

jbalch - Posted - 12/11/2012:  18:20:11

Fun Thread....I love it.

Dan, if you speak to Tom Morgan again - tell him hello for me.

Back in the 1970's we played some shows at his place near Dayton, TN. I had not seen Tom in many years ... then out of the blue he sent me a very nice letter of congratulations when by second CD was reviewed in Bluegrass Unlimited Mag.

Here is a facebook photo of us (The Pure Mountain Water Band) on Tom's KIUKA KUNTRY stage in 1978.

sphotos-b.xx.fbcdn.net/hphotos...856_n.jpg

Dan Knowles - Posted - 12/11/2012:  20:46:21

David,

I'll be sure to carry you around and show Paris to you...it's a real special place! We've even got an Eiffel Tower!

Jon,

I'll be proud to have you come for a visit! Any other BHO members too!

Hay, Tommy, I wondered where you had gotten off to. It's good to hear from you. You still can build that guitar of your dreams!

John,

I will do. Tom was telling me that back in the day he felt that he had the record for destroying more Gibson tenor banjo necks than any one alive... don't know if that is quite true but I do know for a fact that he sold me about 300 bear claw figure sitka spruce top sets that had been milled by Martin back in the late 1950's.  It is a collection that I am constantly digging into. He is a special guy.

Dan Knowles - Posted - 12/11/2012:  21:07:32

11 December 2012

Today has been a busy day but I thought y'all might enjoy seeing just one of the many projects from today. Tommy Ogle's lap steel complete.

If you'll recall I had to do some electronics work, set it up, install a strap button, clean it and make a new cover plate which I started in an earlier post.

Here I'm drilling the cover plate for screws...

Preparing to paint the back side.

and screwing it down.

Next I drill for the strap button and screw it on...

Now I get to enjoy the fruits of my labor as I catterwahle a tune from it!!!

See y'all tomorrow!

DEmery - Posted - 12/12/2012:  03:17:29

That is a cool little piece Dan. There is lots of music in those little lap steels. David E.

8thpol - Posted - 12/12/2012:  14:45:21

Fun posts......... thanks

Dan Knowles - Posted - 12/12/2012:  16:48:59

David,

I was certainly havin a good time scratchin' out a tune. Tommy came by and picked it up today... it was sure good to see him.

Dan Knowles - Posted - 12/12/2012:  16:50:34

Steve,

Thanks!

Dan Knowles - Posted - 12/12/2012:  17:38:12

12-12-2012

Today was a good day... I like good days Several friends dropped in this afternoon and a lot of work got done.

I performed a set up on a classical guitar today. I'll show some photos and lead us through because most of this apples as well to banjos. Soon I'll do one on banjo set up and post it here.

First let me give the disclaimer. This is how I do it. It may not be the way anybody else does it but it works for me.

Setting up a stringed instrument goes like this.

1. 
   Set neck relief. Fret the outside strings a frets 1 & 12, look at the distance between the string and the 6th. fret. There should be a few thousandths... How many? I'm never quite sure because this is something I don't measure. I've done this often enough that I can tell by just looking. Much of what I do is by experience and feel.


2. 
   Adjust the nut height. I do this by fretting in the space between frets 2 & 3, the string wants to just miss fret 1. Heavier players require more space. Again as above...  grab a saw  or file and go to town!


3. 
   Lastly adjust the saddle (or bridge height). As above...

The first thing I do is an inspection so here I take a look see inside with my handy dandy scope. I really like this thing...

I didn't need to work on the neck relief so right to the nut! Checking string height...

Hooking the string out of its groove...

Deepening the groove. I'm using a Stu Mac nut saw. I've got a whole set of these and boy are they handy.

What do you do if you go too far you ask. Fill it up with cyno and baking soda. Then re cut it.

Test drive to see if it worked!

I was lucky this time, it all worked. So I cut off all the strings and use the KNOWLES SECRET SAUCE to treat the fingerboard.This preserves and protects it. Remember don't ask what it is .... it's a secret!

Next I file the nut down. It should be where 1/2 the sing is in the nut 1/2 out or above. Sometimes this works perfectly.

My good friend (and original ALMOST BROTHER) Nick Nichols came by to help me put the finishing touches on the classical guitar setup! We thought of doing Bauch, but this was more fun!

I did a make up lesson with Bob Tyler. Here he is with his Knowles Banjo!

Dan Knowles - Posted - 12/13/2012:  20:01:45

13 December 2012

Today two  banjos wondered out of the shop. One went with its owner and the second shipped out with UPS (disclaimer this add was not paid for by UPS any of its employees or owners).

Here is the first being presented to Hunter Garrison of Murray, Kentucky. It is a neat old banjo, 1880's or 90's. It was his Great , Great grandfathers, Factory built probably by Buckbee. It has a very cool neck/ heel joint cut very much of that time period.

When the banjo came into the shop it was in very bad shape, totally unusable. The neck was loose and it got a new all be it aged head a cleaning (without destroying patina), a couple j hooks & nuts, violin type tuners and strings. It was a mess... Ya I just drove a new banjo underneath it.

Here Hunter is grabbing his banjo from my sticky hands....

Here is something you might find interesting, I made several banjo bridges for the UPS sent banjo and I got some photos of the process.

Here is how it went;

First I worked up the wood, both the base and cap. The glued them together. I used cyno. I like using this glue for bridges. It costs a bit more than Titebond, epoxy or even hide but its property of brittleness makes it worth the expense. It is brittle like well made hide glue but is not as heat sensitive. The brittleness allows for the transmission of vibrations whereas most other glues can be a bit rubbery and so dampen vibrations. Allowed to cure without accelerators it is one of the stronger glues we have. 

After being laid out inner holes are drilled.

Then the waste is band sawed out.

Cuts are cleaned with this little Dremel router.

Then the bridges are thickness sanded, shaped and lastly string slots are cut using gaged nut saws.

Finally a few photos of the other banjo the one that shipped today. These photos were made a few weeks ago before the banjo was finished.

And finally together and being played for the first time.

See y'all tomorrow!

dbrooks - Posted - 12/14/2012:  17:13:06

Great photos, Dan.  I had a big smile watching Hunter accept his great-great-grandfather's banjo.  I play my Bay State that you prepped for me every evening.  While it's new to my family, I do wonder about its untold story that's over 100 years old.  Certainly, you're an important part of that now.

David

Dan Knowles - Posted - 12/15/2012:  03:59:38

David,

I always wonder about the stories the instruments that come through my shop if they would, could tell. In addition to the responsibility i have to my clients, I feel a great responsibility to these instruments themselves. They are a voice. They have been and will be someone's voice if maintained. 

Dan Knowles - Posted - 12/15/2012:  05:24:13

14 December 2012

I'm posting this 'un a day or rather a morning late... Bed called early last night. But now I'm up and posting.

Today will be an interesting day. When I get to the shop I'll teach my Guitar building class and (hopefully) Jerry will finish his (first) guitar today. It is an electric, that is a take off of a short scale Danelectro from the late 1950's.  Hopefully great progress will be made by everyone else and perhaps I can start preparing wood for the d'Amore. 

Anyway this post is suppose to be about yesterday and not today, now isn't that one a quandary?

I worked on and completed a banjo today that I think is worth of a bit  more detailed interest than normal so I'm going to stretch one day's work into two posts... this morning and tonights. It is an interesting instrument  1880's-1910, more likely earlier than late. My client wanted the head preserved with the rip (all be it repaired),  all of the patina retained and the tuners aged and primitive.

The head was repaired earlier with a piece of an old hide head with lots of personality, hot hide glued to the under side of the old head and gut strings sewn through old previous wire repair holes. Re-ageing the head was required where patina was removed slightly during  gluing. Hide glue is water based and so it slightly lifted some of the dirt from the surface.   

The rim was also repaired earlier with hot hide glue where it had started to delaminate.

So on to todays work....

Here is the head/ rim. The head repair need to look as if it had been compleated a long time ago so I used a old piece of a banjo head that had a good deal of color to it.

One of the ways I re-patinaed it was to dump some used wet espresso grounds on it, leaving everything to dry. It left a very subtle discoloration. 

The rim underside...

Because of the rim repair some slight fitting of the dowel stick hole was required. I'm using a sharp chisel to pare away a tiny amount of wood.

I gently tinted the gut "threads".

Then frenched in a bit of shellac. Then I rubbed it with my bare hand to deaden the new gloss...

And installed the neck...

Next it was on to tuner turning. I'll turn a basic shape on the lathe, then doctor it. These are being turned from Walnut with one from Osage Orange for variety!

More Later....