diggerman - Posted - 09/10/2013:  13:02:33

One of the most interesting items I've read for ages. I hope you continue this thread so we mere mortals may get some insight into the true mastery behind our beloved instruments.

Noah Cline - Posted - 09/10/2013:  15:44:57

Been following this thread. It's been great to see a master builder at work.

Dan Knowles - Posted - 09/10/2013:  20:05:33

Sandy & Noah,

Thanks so much! Welcome aboard the Luthier's Life boat!

Dan Knowles - Posted - 09/10/2013:  20:37:08

YADSEUT

Have you noticed the color change? Are your from Scotland or Ireland? Have you ever raised your hand in a public gathering? Do you wonder about the density of air? How many notes are in the average banjo break?

It's odd but the "J" key on my computer keyboard sometimes sticks making Banjo into Bano...

Tuesday and I just got in from causing my students (victims) to suffer... And so now you are wondering about my day... It was quite good! It's just that now it's a bit late for the old man and I get a bit whacky.

Well here is what hit the CD changer today (along with the prelude for a new musical that I'm working on). John Hartford, Allison Brown, Guy Roberts & Edgar Cruze. Good stuff!

A good friend of mine and regional "Guitar God" John McDaniels franticly called me this morning in hope that I could duck tape his Tele back together for a show with Waylon Jennings old band on Saturday night. The jack had failed. I see this more often. In an effort to save money lots of manufacturers have gone to cheaper and more fragile parts. Two years and the jack was shot. Completely. Your think that at least USA Fender would use Switchcraft... 

Anyway as I was workin' on John's Tele I had a surprise, He plays banjo and well! He grabbed down my old Minstrel and wet to wailing! What a treat!

Here I'm cleaning & polishing frets on a Martin D-18...

Polishing a Takamine 12-string guitar after some finish repair...

Spreading some of Dan's not so secret sauce...

And installing the tuners... Well this is about as far as I got on this one before Betty, Dallas, Regina, Denton, Bob, Will, Mike & John started arriving for their weekly abuse!

Happy trails to you, until we meet again...

rparker4 - Posted - 09/11/2013:  07:19:28

I was playing my banjo last night and got to thinking about all the time you put into it. I then remembered how you used to post on thebanjohangout so I logged on and bam you're still on here! Excellent blog by the way! Makes me feel back home in your shop! Hope all is well and I'll try to stop in the next time I'm in Paris.  

Richard Parker

Edited by - rparker4 on 09/11/2013 07:19:49

Dan Knowles - Posted - 09/11/2013:  10:32:52

Richard,

Great to her from you! I see your dad around town and he keeps me somewhat up on your world... still I would love to see you.

Do you remember this? ( for everybody else, This is Richard putting some Mumbo Jumbo on Orpheus neck)

Do you still have your Bacon & Day knee mute on the banjo? Do you still use it?

Edited by - Dan Knowles on 09/11/2013 10:36:37

rparker4 - Posted - 09/11/2013:  16:54:10

Sure do! I would love to play Orpheus again if you still have it. I still have the Bacon & Day knee mute on my banjo and I still use it! I'll bring my banjo with me and let you see it.

Dan Knowles - Posted - 09/11/2013:  18:43:37

HUMPDAY

Wednesday already  and man is this week flyin' by. I've been accomplishing quite a bit still the work awaits... We are presently getting ready to leave to go to our granddaughter Anna's birthday celebration... she's seven this year. It was only yesterday...

Back from the party, a great time was had by all and the post continues...

The 12 string Takamine was strung up, tuned up and kicked out today. Here I'm checkin' it out, ya, it's alright.

I dove into workin' on this James Patterson guitar (from Santa Cruz, Ca). It had a loose fret. A very, very nice guitar and all.

Some sweet inlay.

I tried banging the fret in, gluing it down, nothing worked. So I pulled it. I melted the glue using this soldering gun. The electrodes are hollow ground to fit on the top of the fret crown.

The new fret in, all are leveled with this diamond hone...

My client came to collect his instrument. This man is a true musicians musician! We sat and traded songs for an hour or so.

I started routing for the pearl on the new Pharaoh neck. Here is my Dremel rig. The Fordem's brushes are going bad so I traded to use for this. Low tech but it works.

Checking the fit...

Routing on the peghead...

SEE Y'ALL TOMORROW

Dan Knowles - Posted - 09/11/2013:  18:45:20

Richard,

Yes I still have the Orpheus banjo and you will be more than welcome to play it!

Dan Knowles - Posted - 09/12/2013:  17:52:11

THURSYAD

The inlay project moved along smoothly today. The routing was completed and inlay was glued in. We'll see how it turns out tomorrow when I sand it.

This is the way that I normally rout for inlays. I stand in front of the French doors for light,  using this converted hospital table to support the work and go to town.

Because I am inlaying pieces of differing thickness all of the pieces have small pieces of wood glued to them. These hold the inlays flush to the surface.

Thirty minute set epoxy is mixed with a small amount of burnt sienna & black acrylic paint to tint the glue.

The first batch of glue is gone, time to make more...

Most pieces don't need clamping these long strips tend to hump up.

After several hours the glue has set up. I find it easier to knock off the blocks at this point.

The blocks removed now the neck is left for the glue to cure over night...

TOMORROW...

DEmery - Posted - 09/12/2013:  17:58:49

Dan I never cease to be "beggared" by your work. David E.

Hawgfiddle65 - Posted - 09/13/2013:  05:32:12

Hi Dan

Here's a question for you. Result of a lunchtime chin-wag with a colleague

Your instruments are wonderful creations .  You couldn't have just arrived at that point of expertise straight way .How long did it take or how many instruments did make before you said to yourself ,'Hey ,I could probably sell that !'  Did you train as al uthier.

Jim(Hawgfiddle65)

Dan Knowles - Posted - 09/15/2013:  06:53:08

David,

Jim,

Thanks. Well expertise sure didn't happen too quickly. That said, the first instrument that I made was a lap dulcimer. I was maybe 14 or 15.There was a violin builder/ repairman who moved to our town. I was fascinated by his work. I'd go to his shop to watch him work. One day he sold me a dulcimer kit ( the plans were found in the local library). My dad and I built it and a few month later somebody wanted it , so I sold it. That got me started and like an old drunk I can't figure out how to quit!

Dan Knowles - Posted - 09/15/2013:  07:25:02

FRIDAY - SATURDAY

I have had two wonderful days!

Friday afternoon Mr Craig (Frailin) Evans arrived in Paris to do an interview for his Luthier series. I've been interviewed several times (last time by a highway patrolman!) but few have been this in depth or thoughtful. There is nothing quite like a smiling face asking deep questions to open a person up. We spent the evening talking a wide rang of subjects from Banjos to Asburgers syndrome. Marketing to painting. Craig is not a fell who settles for mono-dimensional conversation. Needless to say we talked late into the night.

Saturday it was lights, cameras and action. Craig and I spent a couple of hours yacking, this time on film. We wondered around the shop, picked a bit and talked to my lutheri students.

Here we are along with my grandaughter Amber... BTW Craig, I love that shirt!

Meanwhile in the next room Kevin (Steve) was working on his box...

Soon Amber started sand jointing her Cavaquina back & sides...

And Eric completed his peghead inlay!

After the shop work we went home and had a birthday party for our twin grandboys Keaton & Braden. There were over 20 folks here, it was a house full! Here I'm holding Calib (Sam & Rachaels son) and Sophie... quite a combination!

Cake time with most of the local cousins and all the neighbor kids (this was all I could get in the photo at one time!).

Later that evening the boys wanted a marshmallow roast. It was a perfect capper to a great day!

(Again) MORE TOMORROW...

dbrooks - Posted - 09/15/2013:  07:32:03

I am delighted to hear that Craig Evans (Frailin) has filmed an interview with you.  Craig's Builder DVDs are excellent, and I really look forward to seeing your episode.

David

frailin - Posted - 09/15/2013:  16:44:32

Thanks, friend.  But a comprehensive interview of you would take MUCH more than two hours!  You are truly a multi-faceted renaissance man!    Yes, we talked about some thoughtful, meaningful stuff, but there are so many entertaining tangents of things you're into that we COULD have taken.   No matter.  This show WILL be one of MY favorites for sure.  

Thanks for doing what you do for all us banjo players, builders and lovers of this music, Dan.  Your contributions are enormous.  Humbled we had a chance to share some time.  

Carry on, sir!  

Craig

Kaelri - Posted - 09/15/2013:  18:12:02

Sounds like a great documentary! My family and I were wondering how and where we can see it?  (Still hoping to see the one you filmed for earlier this year also for a channel on TV) 

Ellen

Dan Knowles - Posted - 09/16/2013:  06:03:41

Ellen,

I'm not sure when either will be out but I do know that you can follow Craig on his travels (and know when it is out ) on this forum Banjo Builder Interviews - My 60th Birthday Present...here is a link...

banjohangout.org/topic/202324/45/#3410082

Ho C Ying - Posted - 09/16/2013:  06:23:14

Craig, please tell me you did remember to ask Dan to play one or two tunes before your camera!

Ho C Ying - Posted - 09/16/2013:  06:27:08

Dan, I like the picture of you holding Calib and Sophie!

Dan Knowles - Posted - 09/16/2013:  06:36:29

PLASTERED-SUNDAY

Yep I got plastered this Sunday... ah or rather I plastered on Sunday. We've got this old house (ca.1900) that we are restoring. So we've moved into the bathroom to remodel it and now I'm attempting to repair the plaster walls. These are the biggest patches that I've attempted to date. My grandson Chandan came by and laughing shot these photos!

More soon!

Dan Knowles - Posted - 09/16/2013:  06:37:56

C Ying,

Yes Craig kindly asked me to play a couple of tunes. I liked that photo too!

Will1717 - Posted - 09/16/2013:  07:19:02

Dan:

Looks like you need some help with the plastering. If you can hold me vertical I'm pretty good with a trowel! 

Dave1climber - Posted - 09/16/2013:  08:04:47

Bill

I hate plastering, but I could hold you vertical while you plaster!!    

That would mean that we would have to coordinate a trip to Paris Tenn.    

Dave

Kaelri - Posted - 09/16/2013:  10:07:02

Thanks for the link on Craig's thread. 

That picture with all that exposed lath behind your head looks awful big! When we end up with spots that big, my husband does not know if it is patchable, so he tears if all off to start over, (later). If you are successful with that large of a patch, maybe we will try the same and save ourselves time.  We are all about doing it right, but not working harder than we need to. ha.

Ellen

Dan Knowles - Posted - 09/16/2013:  10:54:36

Bill & Dave,

COME ON DOWN!!!!

Ellen,

That was a very cool pocket window. We tried to figure out a way to save the window and use it behind the new shower unit, but just couldn't. So we pulled the old one out, put in a small window and lathed over the hole. In the next few days I'll try to finish plastering over it.

Dan Knowles - Posted - 09/16/2013:  16:33:38

PEARL ON MONDAY

I wasn't fully pleased with the way Pharaoh 2's inlay was feeling... it needed something. Perhaps a bit more light movement or energy as my buddy Craig would describe it. So I spent most of the day installing a whole passel of tiny pearl dots and some lines...

First I measured the dots, .094...

Then I measured a drill bit. Lucky guy it was also .094.

Then I went to drillin'.

First I place the dot on the hole then drive it home...

I thought that the base needed some dots too ...

After all of the dots got installed I routed for binding and installed that too. Unfortunately the cameras batteries ran down so I didn't get all of the photos I'd have liked. Here I'm gluing in the binding and purfling...

There it is, bound and inlaid!

Again, tomorrow...

Dan Knowles - Posted - 09/17/2013:  21:03:47

9-17-2013

I just walked in THE HOUSE from roasting the coffee beans, teaching banjo and talking to my daughter Jenny in California. Oh yes I also worked in the shop and had a nice long conversation with my Washington state pal Tom Bergan.

On to today's photos...

I'm going to be cutting the heel on the Pharaoh 2 banjo's neck heel after I get back from this weeks traveling. I'd been thinking about making this change in my heel cutting jig. It is an added bed to support the neck during cutting.

After figuring my demensions I got a block of maple and went to town cutting...

After cutting and fitting the bed is glued to the jig.

Then off I went to a couple of hours of buffing and finish sanding...You'd think it would go quicker with the buffer....

Another banjo is in the works and so I started preparing the pearl for cutting. I'm thinking of bringing my boat pearl cutting rig with me on this next trip...I might just make some hay that a-way.

This is a symmetrical pattern and the easiest way to get symmetry is to cut both sides at the same time. So I'm gluing two pieces of pearl together ready for cutting.

Oh yes, mu buddy and student Denton Jordan came in to lesson today with the coolest finger pick, a clawhammer Thimble. It is very nicly made and REALLY IMPROVES THE TONE. Might allow me to give up on the nail job.... here is a link...

thejoelhooks.com/

Did I say that I just came in from coffee roasting? Here is the newest addition to my roasting tool kit. Two pipe flanges added to my Harbor Freight Heat Gun that protect it and help the roasting pot retain its heat. These roasts went quicker and were more even than before! Thanks goes to Joe Snow for this great idea.

Tomorrow, ON THE ROAD AGAIN...

Edited by - Dan Knowles on 09/17/2013 21:10:47

DEmery - Posted - 09/18/2013:  08:23:02

Dan I checked your thread views a moment ago and it was "69,999.!!!" This should make 70,000!!! Congratulations on bringing so much attention to building and what goes on n the day of a luthier..., at least for one in Paris, Tennessee. It has been fun to watch. Somewhere in there Saint Augustine was built but that was months ago and many repairs, builds, and riverboat stories ago. David E.

Dave1climber - Posted - 09/18/2013:  11:08:03

And this should be 70,001.  Keep the posts coming.        

Woodturner - Posted - 09/19/2013:  07:45:48

Hello Readers and Followers of Mr.Dan Knowles.  As you know, he's travelling on the river boat right now.  Dan created a picture he'd asked me to share with you.  Keep playin'...

richla - Posted - 09/19/2013:  12:04:27

Thimble pic: I love mine, and there are threads on it, seems to be pretty popular.
Dan, if you ever get a chance, you should give us a run down on your coffee "system". I thought I read all the posts, it seems you have a top secret system, but I can't figure out what it is you are actually doing, but it sounds interesting.
Great thread here, keep it up,
Rich

Kirk Jacobs - Posted - 09/19/2013:  15:14:20

On page 4 of this thread Dan talks a little about his roasting technique.  It is discussed a couple of times through out the thread.  Hope that helps.

Paul Meredith - Posted - 09/19/2013:  18:25:29

Dan,

I would never have thought a semi-random sprinkling of dots would so perfectly complete the rest of the inlay design which is quite structured.  Nice!

Edited by - Paul Meredith on 09/19/2013 18:25:57

richla - Posted - 09/19/2013:  19:18:21

Kirk: thanks!

Kaelri - Posted - 09/19/2013:  20:07:40

I agree, the dot inlays do bring the whole design right around and make it (the inlay design) just right. Mighty fine. 

northwoodspicker - Posted - 09/20/2013:  18:28:46

I love following this thread-you've got a great job man. What more can you tell me about your root beer recipe?

Dan Knowles - Posted - 09/20/2013:  18:36:17

THANK YOU!!!

FOR STAYING WITH THIS

LUTHIER'S LIFE!

70,000 reads... back when my friend David Emery suggested the idea of this post I never would have imagined that there would be this many folks interested in my life. If you have enjoyed this post so far please let David know about it, his idea made it happen!

Noah Cline - Posted - 09/20/2013:  18:42:52

Great idea, David!

I've been enjoying this thread even before I joined BHO.

Btw, Dan, I like the pearl dots. It sets the fret board off along with the other inlays. The range of colors is nice, too.

Edited by - Noah Cline on 09/20/2013 18:47:52

Dan Knowles - Posted - 09/20/2013:  18:57:27

Denton,

Thank you for posting the photo. Being without good internet on the Queen of the Mississippi nearly drove me crazy! Good thing the text messaging still worked!

Rich & Kirk,

I guess Kirk beat me to punch on this one.... I saw you post and started figuring how I'd shoot some photos of the coffee roasting... then Wala! Kirk saved my bacon (and a lot of work too). Thanks Kirk. One added note should you want to pursue the coffee roasting,  This new heat gun (from Harbor Freight) is a big improvement over the Wagner. The heat shields that were made from the plumbing flanges are a must. They will save the plastic housing of the gun and they also increase the heat holding ability of the pot (because they partially cover the top of the pot). This dramatically speeds the roast.

Ellen, Paul & Noah,

Thank you for your inlay comments. 

Joseph,

I'll try to remember to follow the process here on the BHO next time I make some. I'll also try to remember to find an post my current recipe. The recipe changes all the time as Joe and I refine it. Mostly it is Sassafras root, Wintergreen, sugar (or some other sweetener),  yeast and water. It is one of the more interesting drinks that one can home brew in that even the most traditional or Old Time recipes vary greatly.    

Edited by - Dan Knowles on 09/20/2013 18:58:32

Dan Knowles - Posted - 09/20/2013:  19:43:02

ON THE ROAD AGAIN

(2 DAYS LATE)

I'm sure that y'all have figured out by now that I've been out performing on the Queen of the Mississippi for the past couple of days. I am writing this post back home in Paris.

My wife Debra, my pal Tyler Andel and I had a great trip as we drove down to Vicksburg, Mississippi on Wednesday to perform on the Queen. We made a stop in Memphis for lunch at a wonderful Indian restaurant called the India Palace. The food was GREAT! If you like Indian food and are in Memphis, it's the place to go! I can't tell you what it was exactly that I ate but I can tell you that it sure was tasty!

Here is a link to their web site...

indiapalaceinc.com/

I realize that life on the road can sometimes seem romantic, wine, wimen, song and all but the truth is captured in this photo. This 'un got took it as we were enjoying a parking lot known as I-40 around exit 12 in Memphis.

Oh... here we are in the India Palace, aren't cell phones great!

After a bunch of hours of driving this wonderful sight greeted us, our home away from home, the Queen of the Mississippi!

You can tell Tyler was glad to be out of the van!

Our nearly two day room. Can you identify the banjos? Can you figure out how many were there? (the answer can be found on page 129)

Here are some photos of my sweet old friend the river Mississippi... It's down a bunch from the last trip although not near as low as when I was on last year in November. Still this river is AMAZING!

More Tomorrow From Paris, Tennessee!

Edited by - Dan Knowles on 09/20/2013 19:44:28

Dan Knowles - Posted - 09/24/2013:  10:45:40

 BACK ON THE RIVER AGAIN

Yesterday Tyler Andel, Eddie Coffey, my wife Debra and I  drove to Cape Girardeau, Missouri. Debbie dumped us off  so we could do a show Monday night on the Queen of the Mississippi. We were traveling down the Mississippi river then up(north bound for your river rats) the Ohio river to Paducah, Kentucky. I'll be doing a show tonight & tomorrow with a different group of villains... my son Sam, Danny Conger, Mark Holladay & Josh Coffey (Eddie's son). Here we are on the river bank in Cape.

Sherry Lynn needed a new set of strings...

Here was my afternoon banjo class. They always do so good. Check out Tyler wit Sherry Lynn in the background.

Cairo point... the meeting of the Mississippi & Ohio rivers. A good spot to fish!

On stage with Eddie & Tyler, it was fun having two banjos in the lineup. It was even more fun having one with Tyler's ability...2013 National Old- Time Banjo Champion, 2013 Grand Masters Fiddle Champion of the United States and several more! We had a wonderful time with these folks!

More soon...

jbalch - Posted - 09/24/2013:  10:54:14

Two National OT Banjo champions in one show.  That has to be a first! ;<)

Dan Knowles - Posted - 09/24/2013:  11:01:35

I don't know if it was a first... but it sure was fun!

Dan Knowles - Posted - 09/25/2013:  13:29:56

PADUCAH KENTUCKY

Tuesday following a very pleasant trip, the Queen of the Mississippi was ported in the beautiful river city of Paducah, Kentucky. Eddie and Tyler after a great breakfast of Kirchoff's best bread and coffee loaded up in their vehicles and headed home. So I wondered the town and what a pretty town it is!

Although I grabbed a umbrella it still rained. Mostly a slow drizzle but wet none the less...

Around 5 PM the guys in the band started to show up and we had a quick rehearsal of The Tennessee River Song and Somewhere over the Rainbow.

8:15 we take the stage!

Here I'm found playing The Pharaoh...

Mark Holladay and his '48 D-18

Danny Conger sawin' away!

Josh Coffey (Eddie's son) with his Gibson...

Here we are again... that's my son Sam on the far right keeping us together on the bass.

Tonight we will be on the Cumberland river between Dover and Clarksville, Tennessee. These are my home waters!

More soon!

Dan Knowles - Posted - 09/26/2013:  07:03:21

TENNESSEE & CUMBERLAND RIVERS

Yesterday I woke to the sound of a river boat entering a lock. I jumped up, dressed and ran outside to find that we were on the Tennessee river instead of the Cumberland.

You see I knew that Dover, Tennessee, where we were aiming for is on the Cumberland river so that was the lock I expected to be heading into. It was great to go through the Tennessee river lock (into the Kentucky Lake) as the rise in the Tennessee lock is much greater than the Cumberland.

Here was something new which I had never noticed in a lock before. Whirl pools forming as water is pumped into the lock. By the way this lock is capable of rising 75 feet although on our trip It looked more like 50 or so feet of rise.

Danny trying to figure it all out...

On the Cumberland river after going through Barkley Cannel,  which connects the two lakes.

Kentucky State Penitentiary at Eddieville, Kentucky. First time I saw this place it was night and I was in the wheelhouse with Capt. Kenny Williams.

"Who lives in that big ole' castle" I mused.

"bout 3,000 prisoners" was the reply.

It still looks somewhat like a castle to me... if they'd just get rid of the water tower.

Barkley River scenes.

Dover to Clarksville soon...

Dan Knowles - Posted - 09/27/2013:  04:51:26

DOVER TO CLARKSVILLE

We managed to make it home yesterday in the wee hours of the morning after having played a concert for another wonderful boat audience. So the rest of the day was spent choosing and editing photos for Craig Evans Banjo Builders series. I never would have figured that choosing a few photos could be so difficult.

Back to Wednesday...

After a beautiful day of boating on the Cumberland River we arrived and spent a few hours in Dover, Tennessee where the boys in the band boarded... that is except Danny who had stayed on board.

The Dover highway 79 bridge...

It is so beautiful that I have to pinch myself to prove that it's all real!

Josh Coffey kicking back!

Our wonderful curse director Andrea has been shooting photos of us for the forum... Thank you for the great work! You are the best!

I love this twin fiddle work that Danny & Josh create. I makes me wish I had Tyler here for a full old time Orkestra!

This little light!

Dr. Coffey wears it out!

More tonight!

CAPT Steve - Posted - 09/27/2013:  13:57:28

Dan--Andrea's on board responsibilities are a bit disturbing!

Aradobanjo - Posted - 09/27/2013:  18:05:20

Hello Dan,

Are you coming back to Cincinnati? I read in the paper recently that Kentucky was encouraging more river boat traveling via the Queen.