Dan Knowles - Posted - 08/23/2014:  06:05:13

FRIDAY

Here it is Saturday morning and again it is Luthier's Life time. Is that like Howdi Doody time?

 Today I'll be teaching and then heading off to Cape Giradeau, Mossouri to play recording engineer for a house concert CD.

 Anyway how's about seeing what happened yesterday. 

Here I'm oil finishing a rim. It's the old  wax on- wax off. Oil on, set up for a minute...

Oil off...

Before I glue on a fingerboard I often like to prepare the neck for the backstrap. Here I'm laying out the cut...

At the fifth fret the backstrap ends by curving away. I'm laying this curve out with a French curve. I suppose I should make a template and make quick work of this. But me, Quick Work! Hah!

Trimming out the waste...

I thickness sand both the back of the peghead and the neck...

Then fair it all together with the orbital barrel sander...

MORE SOON!

Rick Turner - Posted - 08/24/2014:  16:49:36

Don't force that board, get a bigger hammer!

At least that's what we used to say when installing redwood decks with warped 2 x 6's and 2 x 8's!

Dan Knowles - Posted - 08/25/2014:  06:18:13

MONDAY MORNING

Yesterday afternoon after driving in from Cape Girardeau, Missouri I was tired, attempted to do a post. It didn't work. So, I deleted it.  In the in between time Rick had posted commenting on  the batch of photos with no comments. Sorry Rick. Today I'll try and rectify the post!

This post is a continuance of the one from Friday.

We are going to be gluing the fingerboard to the rest of the neck blank. I make most of my banjo fingerboards 2 1/4 wide. Several years ago I was fortunate enough to buy a bunch of 'scrap' Macassar Ebony from a hardwoods flooring manufacturer (can you imagine making hardwood flooring from ebony? Well they did) many of the 'salvage'  boards were quarter sawn and 2 1/4" wide hence...

Here it is being centered on the blank...

The pattern of the fingerboard is drawn on the clamped fingerboard...

So now I know where to drill for my locater pins. I use a brass nail in my drill as a bit... 

In with the brass locator nail. Notice that it is outside the edge of the pattern lines. I'll cut this off later. The reason that I use brass (and these are solid brass) is that later when I'm cutting off the waste from the neck, If I get stupid or lazy and happen to saw into the brass it will only slightly dull my band saw blade. 

Epoxy is used and the clamps go on. This caul is from a handrail drop and is one of my favorites. It came from my son who is a master stair builder. The bottom of it has been planed and sanded perfectly flat.

There tiz... Today I'll remove the clamps and maybe make up and glue up the backstrap.

MORE LATER TODAY!

Rick Turner - Posted - 08/25/2014:  10:31:21

Dan, the real trick is using the offset base that is available for a number of laminate trimmers. amazon.com/PORTER-CABLE-7312-O...0000222Z5 Not cheap, but neither is a neck reset.

Dave1climber - Posted - 08/25/2014:  12:31:57

Dan

Which brand / type of epoxy do you use, and where else on your banjo's do you use it?  Also what is the open pot time with your epoxy?

Dan Knowles - Posted - 08/26/2014:  06:21:03

Rick,

Thanks for the link. I have never seen one of these offset trimmers before. I was not sure how I'd get around the fingerboard extension, now I know.

Dave,

System Three T-88. I don't remember the quoted open time but I neve allow myself any more than about 15 min. to do whatever I'm intending. Mostly just in neck construction although I do use it for inlay work.

Dan Knowles - Posted - 08/26/2014:  06:45:38

QUICK POST BEFORE HEADING TO THE SHOP

I guess the title says it all. Mostly today I'm going to let the photos do the talking.

Yesterday I made a caul for gluing backstraps. I've meant to make one of these for years. Instead I've improvised and improvised. Today it got written down!

The caul is made fro 4 pieces of hardboard or masonite (as it used to be called) thicknessed to around .060, bent and glued together with 3/4" X 3/4" kleets of plywood glued to the upper side.

Here I thickness the masonite...

And add the appropriate bends...

Glue..

Gluing the pieces together...

Gluing on the kleets...

After the caul was all glued & trimmed up leather was glued to its facing side. Next I epoxied the various veneers to form the backstrap. On this one it is Brazilian rosewood, maple & Maccassar ebony...

All of the glue applied on goes the caul...

Clamping. The caul spreads out the pressure...

I wanted to see if my new caul had done its job correctly, so after about 7 hours of curing I visited the band saw... 

MOORE SOON!

Dave1climber - Posted - 08/26/2014:  10:25:57

Dan

That caul makes doing a back strap look easy, however I believe that your skill and experience contribute about 90% of the ease.  

Dan Knowles - Posted - 08/27/2014:  20:23:26

Dave,
Thank you I sure appreciate that.
I'm having some trouble right now with my computer, the battery has gone bad bad so I'm doing this short post on my cell phone. Times are crazy. I was always told not to buy the cheapest thing, but I did it anyway .

I bought a new battery for the Apple. It died after two weeks.
UAs I haven't figured out how to post pictures with this phone yet I'll just leave the posters this until I can borrow another computer to post with.
I hope to see y'all here soon.

kwl - Posted - 08/28/2014:  05:32:57

Dan, I tried buying and using non-Apple batteries for my MacBook Pro and was never satisfied. I bit the bullet and purchased an Apple battery and have never had a problem. I know it costs three or four times more, but it certainly saves in headaches and frustration. I continue to enjoy all your work and posts.

Ken

Dan Knowles - Posted - 08/28/2014:  06:25:14

BIG POST/ I'VE GOT ONE THAT WORKS!

It feels so good to be using a full sized keyboard this morning. Last night's attempt to post using the smarter than me phone was not a complete success. Even though I spoke the post into it, there was still an awful lot of editing of "hay, that's not what I said!" and such on a way too tiny keyboard.

I got the phone to use as a computer when I'm out on the road. Oh boy...

LUTHIER LIFE TIME!

I was taught oil finishing by a gunstock maker years ago. This is my usual, first thing out of the box job.

First using a piece of leather I burnish the pervious days work... 

Then liberally put the finish to it...

Good and wet...

Let it sit for a while, then buff it back off. This happens once every 24 hours until I'm happy with the finish.  I always hang up my rags to air dry. Although I've never personally know of it to happen, I'm told that these things can spontaneously combust. So I always hang them like linen on the line...

On with Tyler's heel cap. This wood all matches the backstrap...

Here we see the laminations...

Sanding the 5th. string cutout true...

And checking...

Sanding the edges of the peghead to true shape. Tyler likes my ebony banjo so I'm doing a similar but different peghead shape...

Shaped & drilled for tuners...

Tyler has a scarecrow shape (I've inlayed for him before) which is (sort of like) his symbol. I'll be inlaying this on the peghead. So here I'm cutting out the pearl for it...

Another day and another go around with the oil...

I LOVE the wood on this neck!!!!!!!

More pearl sawing...

Because I'm creating this inlay in a somewhat improvisation style, I make sure that all the pearl will fit on the peghead and so it is placed with a set of tuners installed. Oh good it fits!

More Soon!!!

etparadox - Posted - 08/28/2014:  10:26:18

Fine work as always Dan. Those necks are looking beautiful. The darkened neck contrasting the turquoise is a stunning sight. 

60spicker - Posted - 08/28/2014:  11:10:50

On the peghead inlay, if you turn it upside down, that topmost glob of pearl resembles - with arms outstretched - Elvis, Jesus or Patrick Star of Spongebob Squarepants. Or maybe not.

Dan Knowles - Posted - 08/28/2014:  19:20:17

Eli,

Thank you!

Terry,

How did you guess it? You got all of them correct!

Dan Knowles - Posted - 08/28/2014:  20:05:12

THURSDAY

Designing the fingerboard inlay.

This is fun! Tyler has given me free rein to do anything that I see in my minds eye, as long as it fits with the theme of the banjo. Now as you will remember this banjo is to be named the Scarecrow & the Shipwreck. Well we have got the Scarecrow (along with Elvis, Jesus & Patrick) already on the peghead. So now it's time for the shipwreck.

Well I'm taking a bit of liberty on this point. 

The greatest single marine time disaster in the United States history was, no not the Titanic (U K). The year was 1865 the twenty-seventh day of April. Just north of Memphis, Tennessee on the Mississippi river the steamboat Sultana blew her boilers, sinking and killing  around 1700. These were soldiers, most of who had been prisoners of war in the infamous Andersonville prison camp in Georgia. Because of the killing of President Lincoln crowded out the news of the disaster and the fact that the nation was desensitized to death it didn't have the impact as it would have in other times.

So this is the shipwreck I've chosen to depict. 

First I started with an engraving of the sinking from a contemporary newspaper. This was enlarged.

...out onto my makeshift light table and covered with a piece of tracing paper. A tracing is made, with the thought of what materials are to be used and what arias of this are to be engraved....

The finished tracing...

In the computer, where using Corel I crop, resize and work to fit the image into a fingerboard size...

As I have more control with a pencil than a mouse so the image is printed and I finish filling out the image...

Meanwhile back at the ranch...

I have painted the peghead face with white tempra paint...

I'm gluing the cut pearl pieces to this white paint for scribing...

On with the Scarecrow...

I'll be going to Nashville tomorrow, but I will try to scribe and the remove the pieces in preparation for routing the cavities before I leave out.

MORE SOON!

Edited by - Dan Knowles on 08/28/2014 20:10:13

rubicon - Posted - 08/29/2014:  04:44:00

Dan WOW that neck is beautiful I concur the stain is gorgeous !!!!!!!!!!!!

Ross - Posted - 08/29/2014:  11:05:50

It's a joy watching you create such a beautiful work of art. I look forward to each installment.

Dan Knowles - Posted - 08/29/2014:  18:00:23

Rubicon & Ross,

Thank you for your kind comments. It is things like this that make doing this post wonderful & worthwhile!

We Just got in from adventuring up to Music City Nashville, Tennessee. Where we visited with my great friend and compadre Tyler Andal, the good folks over at Carter Vintage Guitars & a couple of contemporary  art galleries. There should be some interesting news coming soon because of these visits. Of course you my friends here on the Banjo Hangout will know first.

Tomorrow I'll start the day with a Lutherie class and perhaps I may even rout for some inlay... never know. But I'll see you very soon! 

Edited by - Dan Knowles on 08/29/2014 18:01:09

DEmery - Posted - 08/29/2014:  18:11:42

Dan the Pine Cone neck is looking really nice. Knowing first hand how that particular wood and stain looks; it is hard to beat. I nearly got a look at the fingerboard now that it is fretted. I couldn't tell; but it appears the frets window paynes the dots and works to give it framing. I like it...for what it is worth. Look forward to seeing when it is assembled. David E.

PS: That heel carving is one of the best I've seen you do....and I've seen good ones.

Dan Knowles - Posted - 08/30/2014:  16:15:01

David,

Thanks for your nice words. I hope tonight's post answers your wish!

Dan Knowles - Posted - 08/30/2014:  16:36:20

SATURDAY

Bending sides. I know that statement might just drive off the ones who only wanna see banjer stuff. But none the less that is how we started out the day. Kevin's new guitar is going to have laminated sides and so instead of just two bends we have seven! 2 Zebrawood (sides), 2 Spanish cedar (sides)and 3 Masonite (cauls). Here Kevin has got the side bending machine set up and ready to bend the first of the sides.

Me playing instructor...

David, here is the answer to your request!

Ultra fine synthetic steel wool is used to smooth out the surface prior to the next oil coat...

Oh the speed of that hand!

Another coat of oil applied, allowed to set up for a moment and now buffed off...

After the cloth buffing I use a technique which I was learned from an old gunstock finisher.  I burnish the surface with my hand. The finish is quickly rubbed until it becomes so hot that I can't stand it. 

All of the hardware has been allowed to sit, wait on as the patina continues to develoup. The surface is kind of a blue/ green dusty color. This is mostly cleaned off with this old toothbrush.

More Tomorrow!

guitarman8491 - Posted - 08/30/2014:  18:13:05

Dan that neck looks fantastic..can't wait to see it mounted to the pot.

DEmery - Posted - 08/31/2014:  03:00:58

Right Dan...the inlay dots work differently after fretted. Thanks for the update photos. David E.

Dave1climber - Posted - 08/31/2014:  07:15:54

WONDERFUL!

Edited by - Dave1climber on 08/31/2014 07:17:14

Dan Knowles - Posted - 09/01/2014:  05:43:12

Doug,

Thanks. I can't weit to see this one up and going too!

David,

You are so welcome.

Dave,

Thanks

Dan Knowles - Posted - 09/01/2014:  18:04:21

LABOR DAY

I talked to my ole' buddy Bill Rickard today. Like me he was laboring on labor day. It's fitting somehow. By the way I'm not sure if it was Labor Day  today in Auora, Ontario in Canada...

Still here is just a pinch of my laborin'...

I don't even figure that many words are needed for such astute banjo persons as yourselves. So herewith I present the

Nearly Silent Post.

More Tomorrow!

Edited by - Dan Knowles on 09/01/2014 18:06:09

Carl Arcand - Posted - 09/01/2014:  19:16:12

This banjo is going to be a real beauty. 

Today was labor day all over Canada too. 

I figured that since no one is paying me that holidays, I had to work .

I prepared 5 neck blanks out of black walnut and curly maple rough 8 years old billets, fretted one fingerboard, cut 2 headplates, Glued the fingerboard and the head plate on a neck blank,  Prepared and stained 2 banjo pots and finally at 9 PM, cleaned the entire shop. 

That's was a great labor Day. 

Cheers!

DEmery - Posted - 09/02/2014:  03:24:41

Dan where did you get the head with an old mark from John? David E.

Dan Knowles - Posted - 09/02/2014:  05:00:52

Carl,

It sure sounds like you had a busy, busy day!

David,

There are some things only a banjer picker and his nail tech knows. 

Bill Anderson - Posted - 09/02/2014:  08:04:40

Beautiful banjo Dan

Dan Knowles - Posted - 09/03/2014:  02:39:04

Bill,

Thank you!

As I am writing this I've just gotten up (4:30 am) and I'm getting ready to head out to Vicksburg, Mississippi for a ride on the Queen of the Mississippi. It feels like forever since I've been on board although it has been just a few weeks. If the internet is ok I'll post from there later.

See You Soon!

60spicker - Posted - 09/03/2014:  09:19:22

Dan, have you ever made resonator banjos? If so, could you share a couple of pictures? I'm a-thinkin...

Dan Knowles - Posted - 09/03/2014:  15:04:58

Terry,

Back in my misspent youth I did several conventional Gibson resonator style instruments... I'm sure nearly all of us started that way. Anyway the resonators that I currently build are like this one which I did for Tom Bergan's Orpheus banjo d'amore.

bill t - Posted - 09/03/2014:  16:10:52

170,000 reads! Thanks again Dan for this great thread! Bill

DEmery - Posted - 09/03/2014:  16:34:39

Dan you should hit 200K by the end of the second year of this thread. I know it went over 100 pages of fan comments a good while back. It has been fun to watch all that goes on in Pairs......Tennessee. Somewhere along the way I had a banjo or two come out of that shop. David E.

Dan Knowles - Posted - 09/04/2014:  08:22:04

Bill & David,

170,000 reads! Isn't that amazing. Here I am sitting at my computer on the Queen of the Mississippi bumfuzzled by the fact that so many folks are interested in my tiny corner of the galaxy, I guess if folks keep readin' , I'll keep writin'!

casinojack - Posted - 09/04/2014:  08:33:51

Dan

Keep up the the great work.

I read this forum every day.

Jack

Dan Knowles - Posted - 09/04/2014:  09:01:41

THURSDAY

FROM THE QUEEN OF THE MISSISSIPPI

I'm presently sitting at the desk, in my room, practicing a little scale passage from a new tune. It is a re-imagining of Pachelbel's famous Cannon in D. I think once I'm done screwing it up it will be called Banjo Dan's Cannon in G.

I've got the Ebony banjo tuned way down, AGDGg. It is sort of like John Hartford's low  D tuning except the 4th. string is lowered to G and the 2ed. string raised to G. Perhaps it should be properly called Low Double G....

Anyhow this ebony banjo has the nicest deep growl with big strings and tuned like this. Perhaps I should see if Roger Siminoff's new Straight Up Strings will include such a crazy set up as this. Roger, I got my hand up, I'll test 'um!

I drove down to Vicksburg yesterday and had aver uneventful trip, that is if you discount the almost hitting a dear that was standing out in the middle of Interstate 40 east of Memphis, Tennessee. It was a big surprise to start to change lanes and find that the lane I was changing to was occupied by a doe. I got away and so did she!

We have a great bunch of folks on the boat and we all had a big time at last nights show. I'm working without a net (solo) and that creates a challange in keeping folks interested and awake. So I  played through a bunch of different banjos, did some of my regular tunes, added a couple of new ones and told a lot of stories...  and amazingly enough they stayed with me!

This afternoon I'll be teaching a beginning banjo class and then performing tonight. My friend Tyler Andel will be joining me in Memphis for the shows and the ride back to Vicksburg and I am looking forward to it, GREATLY!

Here is a shot of me from last night all dressed up with some place to go...

And then today in the room, practicing Somewhere Over the Rainbow on my Mandora d'Amore...

MORE SOON

Dan Knowles - Posted - 09/04/2014:  09:03:23

Jack,

Thank you so much!

jbalch - Posted - 09/04/2014:  09:14:27

I bet that Ebony banjo sounds HUGE tuned low.

60spicker - Posted - 09/04/2014:  09:15:03

Dan, are you wearing Hush Puppies? They're dumb, you know. Glad to hear you're having a great time.

Dan Knowles - Posted - 09/04/2014:  10:02:01

John,

Huge is not even the term for it! Gargantuan maybe.

Terry,

They look kind of like the old Hush Puppies saddle shoes don't they?  I really like unusual shoes. These came from a very cool men's shop in Memphis. This set though are part of my onboard (sometimes) uniform and are from G. H. Bass & Co. Here is a better shot of the shoes...

Comparing shoes & socks with a guest!

rubicon - Posted - 09/04/2014:  10:12:06

That resonator banjo is really something ! I am lookibg forward to seeing the riverboat Knowles banjo assembled great finish on it

rubicon - Posted - 09/04/2014:  10:14:15

By the way thats some pretty radical footwear !

Paul R - Posted - 09/04/2014:  13:55:58

That's a great tension hoop on that Riverboat banjo!

By the way, we don't have Labor Day in Canada. We do, however, have Labour Day. 

Dan Knowles - Posted - 09/04/2014:  15:20:19

A PROUD

QUEEN OF THE MISSISSIPPI

BANJO SCHOOL

GRADUATING  CLASS 

9-4-2014

Dan Knowles - Posted - 09/04/2014:  15:24:41

Rubicon,

I'm so looking forward to playing this banjo. When I thump the head it feels like it would like to just spring out of my hands. These shoes are very comfortable too!

Paul.

guitarman8491 - Posted - 09/04/2014:  17:25:34

Dan..hope yer having a good time out there on the Mississippi and with all them new and seasoned banjo players. BTW the banjo you made for Tom Bergan is sure a beauty.

Dave1climber - Posted - 09/05/2014:  07:41:48

Dan

Once again as always I have enjoyed your posts.  I read them every day.