Dan Drabek - Posted - 12/15/2012:  15:02:55

Dan, a very enjoyable series.

I do a lot of restoration work, and your mentioning of rubbing the French polished finish with your bare hand to cut the gloss struck a chord. I've done the same thing many times. Glad to see I'm not the only one. In fact, on antique woodworking tools, I've even been known to rub a little garden dirt into the freshly polished surface to blend it in with the remaining finish. Little things like that differentiate the artist from the craftsman.

DD

Dan Knowles - Posted - 12/15/2012:  21:45:47

Dave,

I'm glad to see you here!

Dan,

I'm glad I'm not the only one who uses the dirt trick. Another one I didn't show here was rubbing sawdust (from my bandsaw) into the fresh polish, then rubbing it with my hand to even it out.  I've also found that using oil on my hand as a buff to polish french polish works well too. One has to rub it until it is rather warm though.

Dan Drabek - Posted - 12/15/2012:  22:11:01

One can work a little magic with a dirty buffing wheel too. I think of it as a form of artistic impressionism. In this case, giving the impression of a well aged surface. 

DD

Dan Knowles - Posted - 12/16/2012:  04:27:40

Dan,

I've never thought of that one! How cool!

Dan Knowles - Posted - 12/16/2012:  05:10:33

12 December 2012

My wife Deborah and I went over to a neighbors house last night for a Christmas get together and what do you know our host found an old banjo... you know the rest of the story.

You don't? Oh sorry...

Ok ... well I taught him his first frailing/ clawhammer lick. I love doing that! It is such a charge to be able to pass on something that has given me such pleasure.

Anyhow I was too tired to think clearly enough to write yesterdays post so here I am up before the sun has risen good, waiting for my first cup of coffee.

Now coffee in hand I will begin to pontificate!

Next in my tuner making effort I cut the outside rounds from the tuners on the band saw (not shown). Then went to the belt sander where I rough shaped the knobs.

Here are all of the tuners ready for their next abuse (along with a peg hole reamer.

By the way the taoe is an approxamate depth mark I want all of the pegs to be about the same and this helps

I carve eased edges and marks to give the appearance of hand carving. Well I guess it is hand carved all be it the last surface.

Then beat some burnished & shinney looking arias with a small jewelers hammer .

Reaming the pegholes.

Truing the peg shafts...

Cleaning the 5th. string hole...

All of the tuners fitted...

After drilling the string holes in the pegs have their edges eased. This really helps cut down on breaking the soft gut or nylon strings that will be used on this banjo.

Now fire ageing! I like this photo ... must be my spirit watching over the burn (grin)!

There they are, ready for strings...

Strings on and being trimmed. I know y'all have done this a thousand times but I just liked this photo.

Complete!

Ho C Ying - Posted - 12/16/2012:  06:21:45

Pretty cool! Does this old banjo sound good?

Dan Knowles - Posted - 12/16/2012:  06:50:43

C Ying,

This banjo has been mostly just stabilized for my clients collection. That said I have not attempted to bring the strings to pitch... so I guess I don't really know how it sounds. I would conjuncture though that it would be a sweet plunky and rather quiet banjo .

Dave1climber - Posted - 12/16/2012:  07:19:52

Dan

I do like the way you "age" things to match what your working on.  

In an earlier post I noticed a guitar top hanging on the wall.  The top looks as if it has a strainer attached to it.  What sort of tool is a guitar top strainer?

Dan Knowles - Posted - 12/16/2012:  07:31:26

It's just a strainer I strain fluids through.

walhooey - Posted - 12/16/2012:  23:10:36

really nice info and I can always use it. I really enjoy building and I appreciate all the help people on this site have given me. Now if I could only play a little better.

Dan Knowles - Posted - 12/17/2012:  18:28:53

Gary,

I feel that I should pass on what others have given me.

Dan Knowles - Posted - 12/17/2012:  19:01:01

17 December, 2012

Oh my it was another teaching day today. It began with first of all writing some tabs for a Lap Steel student that just started today. It's interesting the stories folks tell of why they wanted to play an instrument. This fella knew Don Helms (Hank Sr. Drifting Cowboys) and always loved to hear him play ... and so...

After an hour or so of Tab writing my buds that I ride with (THE R.U.F.F. RASCALS CYCLING CLUB) took off for a morning tour of greater Paris. It was about a 10 mile ride. No we didn't go by the Eiffel Tower today. We did take time to pose for y'all outside my shop though.

I neglected to post photos of my Saturday Lutherie class. Here I'm discussing the intricacies of the binding router machine with Eric. Next one, he's doin' it!

Here is the direction for running the router...

And now I'm teaching a bit about electric guitar wiring...

Kevin prepares his guitar for the binding router...

Now on to a few of the days students....

Denton Jordan (BHO member) with his Knowles Fan fret banjo. His has the same pattern as the one I did for Abigail Washburn.

Here was my last student (and a very promising one) of the day,  Dallas.

Dan Drabek - Posted - 12/17/2012:  19:03:54

Dan, you are one busy guy. I'm surprised you have time to post this thread, but I'm glad you do. 

DD

Dan Knowles - Posted - 12/17/2012:  19:24:19

Dan, I usually post just before bed... tonight it will be before I go outside and (like my friend Tom Bergan) roast coffee beans.

Dave1climber - Posted - 12/17/2012:  19:33:54

Dan you seem to have a very full life!! 

Paul R - Posted - 12/17/2012:  19:37:13

Dan,

Not only do you do great work, but you pass on your knowledge. I love your attitude!

The best repair people who have worked on my instruments have been the ones who explained what they were doing (or had done) and gave the time to talk instruments, music, and other topics.

And bicycles and banjos have so much in common - people like to tinker with both!

Keep it up.

Paul

liam_fnq - Posted - 12/17/2012:  23:19:03

I could read a whole forum of just Dan Knowles topics. Thanks Dan

Dan Knowles - Posted - 12/18/2012:  16:28:28

Dave, it sure seams like I do sometimes... BTW  The coffee I roasted last night was a very nice Brazilian... it made for a great cup today!

Paul & Liam, Thank you for the nice compliments... I'm glad you are enjoying this little life.

Dan Knowles - Posted - 12/18/2012:  19:44:47

18 DECEMBER, 2012

Another Tuesday come and gone... just a few days from Christmas and we are nowhere near ready. I think that tomorrow I'll keep the shop shut down and work at the Christmas thing. In addition our Daughter-in-law Rachael (Married to our son Samuel) is probably going to give birth tonight. They say it will be a boy... but you know how those doctors can...

Anyway I said that just to let you know that unless the excitement gets too much I'll still post some tomorrow.

Today was an interesting day. I started the day teaching "Meditational Guitar" to my good friend the great author and cartoonist Joe Snow. His twin sons, Brice and Eagen are the younger cyclists in the bike gang photo. After that I went to the shop and worked on a couple of guitars doing various repairs. The interesting banjo project was this old beauty. Its rim laminations had separated and during the re-gluing developed this crack.

I made and fitted a spline.

Then I brushed some  Hot Hide glue (you can see the glue pot in the background) into the separation.

Then the spline was driven into the crack with a small chasing hammer. You can't see the hammer in the photo cause I'm whackin' so fast!

Clamped and curing.

A student banjo found the bench for a setup. I'm removing those funky, noisy, off balance & useless strap holding rings from the pot.

Next I made a replacement bridge for a guitar.

After the glue cured (and lunch) I started trimming the spline.

This is a little marking knife a blacksmith friend made for me. It takes and holds a super edge. Check out those sweet rolling shavings!

Next a little sandpaper.

Don't do this at home! I'm painting some potassium dichromate on to age the wood.

Dried and ready for finish...

Tomorrow we'll look at a Gibson TB-11.

Dave1climber - Posted - 12/19/2012:  06:23:25

All in a days work, but such nice work!

Dan Knowles - Posted - 12/19/2012:  12:52:43

Dave... yep dats true...

Dan Knowles - Posted - 12/19/2012:  13:21:18

19 December, 2012

I barely went into work today... @ 8 AM we were presented with a new grandson by our daughter in law Rachael and her husband Sam. He looks like a big fella (in the one photo I've seen so far). We plan on making (with our granddaughters Amber, Abby and Anna) a trip to McKenzie, TN today to see the new one. I could just leave it at that and not do much more of a post but I did promise to complete yesterdays forum so here goes....

This one walked in for its checkup and set of ne strings. It's a Gibson TB-11 from the 30's. The neck was (I believe) converted to a 5 string by Tom Morgan. My client bought it in the late 60's early 70's at Gruhn Guitars in Nashville.

Now back to the old banjo rim....

Here I'm brushing a bit of potassium dichromate on a edge repair to age the wood before finishing.

OK, you may think I'm making espresso but don't be fooled, I'm making some stain for a banjo head.

I'm using a bit of coffee to further stain the rim edge... after it dries I'll French polish it.

Now I'm staining a banjo head...I'm using both the espresso and the grounds mixed with some ammonia.

Stained... too bad the cool texture will vanish after it has dried. Most of that is grounds.

Back soon....

jbalch - Posted - 12/19/2012:  13:58:48

CONGRATULATIONS  ~  GrandPAW

DEmery - Posted - 12/19/2012:  14:09:48

Great news Dan. David E.

Tylerb1 - Posted - 12/19/2012:  15:14:30

Congratulations Ole Man

Paul R - Posted - 12/19/2012:  17:07:54

Congratulations - great news!

Shawn Hoover - Posted - 12/19/2012:  17:54:55

Congratulations and thanks for the posts. How about a look at the roaster when you get a chance?

Dan Knowles - Posted - 12/19/2012:  19:02:31

John, David, Bob, Paul and Shawn,

Thanks for your congratulations. We went down to the hospital in McKenzie and saw Rachael, Sam and the new (yet to be named) little fella. Here is a photo of Rachael the baby, Amber and Anna.

Shawn did you mean the coffee roaster?

Dan Knowles - Posted - 12/19/2012:  19:37:54

Shawn,

Well here it is the most high tech coffee roaster on the net. Only Tom Bergan has got me beat for high tech! Heck we ought to for a banjo pickin' coffee roastin' group.

Here is my rig and what I do:

First the rig...

1 green 1  cup measuring device, used tea kettle without the top, nearly worn out Wells Lamont leather gloves and a Wagner heat gun paint stripper.  This set up cost me maybe $35.

I use that green one cup measure to place about a cup and 1/2 into that metal container,I put on those worn out pair of Wells Lamont leather gloves, This sucker does get hot! Then I go outside on the back porch and plug in that Wagner heat gun,  poke it into the pot of beans and go to roasting.

I've used several hot air poppers (Mr.Poppery), they don't last long. I've even used a home roaster that came from Sweet Marias. They just wear out too quick with the amount of coffee I roast. I've used this gun for about 2 years and it shows no sign of slowing down. I feel like I have more control over the roast and I enjoy the sitting down on the back porch and shacking the pan for 10 minutes or so. I find it quite relaxing, I've even gotten where I enjoy the smell of the smoke.

I buy most of my beans from  burmancoffee.com

Good luck and Happy Roasting!

Edited by - Dan Knowles on 12/19/2012 19:39:10

Shawn Hoover - Posted - 12/19/2012:  20:19:31

Ah, look at those proud cousins. Very nice.

And thanks for the coffee update! I tried a paint stripper and a pan a couple times, but it was flatter and I ended up burning a good wooden spoon with the stirring. Oops! Shacking that tea kettle sounds like a better way to do it. I'm glad you're able to enjoy the good fresh joe while you work. There's nothing wrong with the smoke. It just makes the neighbors wonder what's going on over there.

Dan Knowles - Posted - 12/19/2012:  21:05:30

It sure used to make um wonder... Now they know, Knowles is roasting coffee again!

BTW those high sides help hold the heat in. That helps control the speed of the roast. Also I have a thick home made pottery plate. I put it in the freezer a bit before I roast. Putting the beans on that helps stop the roast where you want it. Also fanning the roasted beans helps too.

Dave1climber - Posted - 12/20/2012:  05:49:33

Grandpa Dan it's always exciting when the family gets a new member.  Congratulations to the parents and much joy and happiness to you and your family.

BTW I like your roasting process.  

dbrooks - Posted - 12/20/2012:  17:03:55

Dan, I knew you had many talents, but I never dreamed that you exercised all of them so regularly.  What variety!

That's a beautiful, er handsome, baby boy.  Congratulations to all.

David

Shawn Hoover - Posted - 12/20/2012:  18:19:07

A cold plate to stop the roast. Brilliant. I wouldn't be surprised at all if the exact same piece of pottery finds a use in your lutherie shop, too.

Dan Knowles - Posted - 12/20/2012:  18:59:03

Dave, Thanks!

David B. I don't exercised them regularly, I exorcize them regularly!

Shawn, I hate to say this but nope I NEVER carry that plate to the shop (my wife won't let me).

five_string - Posted - 12/20/2012:  19:01:40

Fantastic post!! Very interesting and informative to a "hobby banjo builder" like me.
I really look forward to more of these posts.

Thank you very much.

Mike Bolling
Rock Hill, SC

Dan Knowles - Posted - 12/20/2012:  19:34:25

20 December, 2012

Well today I only went to the shop once and that was to meet with a client to pick up his guitar. Instead I had fun with my grand kids and then wen Christmas shopping with my oldest grandson Chandan. I enjoyed being out with him but shopping.... well... you know.

I figured since I had no photos from the shop today I thought y'all might like to have a look see at a guitar I built a while back. This ones name is "FOOTPRINTS" it was designed around the idea of the famous poem. My client is a song leader in his church.

This guitar was made with these specs.

Top: Sitka Spruce (bought from Martin Guitar Co in 1960 by Tom Morgan).

Back and sides: Bees wing Bubinga.

Neck: Heavily figured Silver Maple

Fingerboard, peghead overlay, bridge, finger rest, heel cap and etc. : Macassar Ebony.

Bridge saddle overlay & nut: Fossil Ivory

Truss rod cover: Tortoise shell (supplied by a client).

Inlay: Mother of Pearl, Red & Green Abalone, Black lip Pearl, Turquoise and Silver.

More Soon....

Dan Knowles - Posted - 12/20/2012:  19:42:37

Mike, Thanks for joining us! I'm glad you find this useful.

Weitzel - Posted - 12/20/2012:  21:24:50

Beautiful Guitar. The tailpiece and finger rest would lead me to believe this is an archtop, but I can't see any arch to it, maybe because there is no profile view. Am I correct?
Beautiful inlay work, especially the branch and moon going through the sound hole - nice touch. My first two instrument builds were archtop guitars. I've always loved their more sculptural form.
Jeff

Dave1climber - Posted - 12/20/2012:  23:13:19

Dan

One day I am going to have to stop in Paris TN if you can stand a lookie loo.

Great things happen there!!

Dan Knowles - Posted - 12/21/2012:  06:47:28

We love visitors here in Paris! Come on over!

Dan Knowles - Posted - 12/22/2012:  05:22:08

my friend , our friend and fellow Banjo Hangout member Tommy Ogle undergoes his third cancer surgery this morning... please remember him.

jbalch - Posted - 12/22/2012:  05:35:34

Dan I meant to ask about Tommy.  Thanks for the update.  We will keep him on our prayers:

BTW - about that rim you and he were working on in the photo - how did it turn out?

Dan Knowles - Posted - 12/22/2012:  14:13:06

22 December, 2012

The world ended yesterday and I missed it.

Contemplate that if you will. The biggest event in the history of the earth. It happens in my lifetime ... and I miss it

That makes me wonder what other monumental events transpire that I miss.

Well I don't feel so bad.

If you are reading this then I guess you missed it too.

We should form up a new BHO group... BANJER PLAYERS WHO MISSED THE END OF THE WORLD.

We could discuss what it wasn't like....

Enough musings we got business to attend to!

Today at the ole' instrument shop was Lutherie teaching day. We went on a field trip. The lesson was making traditional stains. These were some my folks used to make back when I was a boy. I try to make some every year or two. There are so many things that they used to do, back before the world ended.

What kind of stain was it Knowles... get back to topic.

Ah today it was Walnut and also iron filing stains.

First thing we did was load up in my old van and go where there is a big old Black Walnut tree (Negero Walnutis). It was cold out there!!! 23 degrees! We picked up enough to make a 5 gallon bucket about 3/4 full. We carried it back to the shop and put it on a bench near the heater outlet to thaw. Then every one went back to their respective building projects.

I stuck some old steel wool into a jar and then filled it with vinegar. This will make an iron stain. It will impart a nice grey to ebony black color.

Kevin, on the other hand  went to working on his bindings...This guitar has been a difficult one in that the kirfing has proved itself to be rather difficult.

Eric mitered the side perfiling for his guitar and then began to install it.

Jerry worked quite studiously on the finish of his Dano (Danelectro) take off guitar, but then took some time out to pour boiling water over the crushed (by Eric & I ) walnuts & walnut husks.  We will let this molder a month or so and (hopefully) get a nice rich walnut stain.  I've been told that both of these stains were used on Kentucky Long Rifles back in the day.

We had a very special visitor today. Englishman Andrew Craft from New York City came down for a banjo lesson and got in on some of our building fun!

Here Eric is showing him how he taps to listen to his guitar body as he progresses.

Here Andrew and I discuss "Head Tensioning."

Now on to the pickin' lesson. I show Andrew the way I used to play the banjo ....

Back Before the World Ended!

More tomorrow if the World Doesn't....

Edited by - Dan Knowles on 12/22/2012 14:15:02

Dan Knowles - Posted - 12/23/2012:  08:23:50

23 December, 2012

Well today is Sunday and I'll a good deal of today with grand kids and visiting Tommy at the hospital.

So I figured y'all would enjoy seeing some photos of Orpheus, the Banjo d' Amore that I built for Banjo Hangouts member Tom Bergan...

Orpheus on the peghead.

Hopefully I'll see ya on the eve....

Dave1climber - Posted - 12/23/2012:  19:44:11

Dan

I remember seeing these photos as you were bringing it to completion, I was very impressed then, and I am just as impressed now as I was then!!                                                

Edited by - Dave1climber on 12/23/2012 19:47:06

Dan Knowles - Posted - 12/23/2012:  20:17:24

Dave

Thanks a lot. I'll be starting a new Banjo d'Amore and a wooden topped d'Amore instrument just after the first of the year.

Tom Berghan - Posted - 12/25/2012:  08:15:34

Enjoyable thread Dan! Man - and I sure do love fresh roasted coffee!

Now - as Orpheus' caretaker, I would like to point out something. People (and Luthiers) always get focused on the incredible workmanship and artwork that Orpheus exhibits, but I would like to point out that the cocobolo rim is an AMAZING sounding rim! So, luthiers take note - try cocobolo sometime! And, as an added benefit, look how beautiful it is!!!

Thank you Maestro (Dan)
Merry Christmas to Deb and all the boys!
Say hi to the girls in the salon! ;-)

DEmery - Posted - 12/25/2012:  15:33:45

Tom you may recall that Dan built Goshen for me and it has a cocobolo rim. Really strong tone and attractive visually. David E.

Goshen by Dan Knowles