DEmery - Posted - 01/30/2013:  06:05:26

Dan that adds to the interest in this build. The wood is more than 50 years old and to know it was originally in the Martin factory is pretty special. I know some of the tops that had bear claw graining, etc., would have been considered as 2nds during that period but is seen as desirable by some today visually. Things really do change in this regard. Thanks for letting the Brazilian Rosewood go into this slot head. David E.

Dan Knowles - Posted - 01/30/2013:  06:23:39

1-29-2013

Day late and a dollar short I'm getting this post up... We had one heck of a storm last night. Loads of wind & rain. There are limbs out of some of the big trees around here. Fortunately no tornados around here although they were called for. The storm made it difficult for this fella to concentrate.

On to the day...

Joe Snow came in for his guitar lesson and stayed to help thickness the back and side wood for the wooden topped d'Amore instrument.

After a bit I went out with the fellas for a bike ride and Eagen caught me in a pensive moment after several miles of peddling.

I'll be building 20 small banjos (17" scale) that need to be completed by the 2ed. week of April. So I am quickly designing and creating patterns for the project. These will be quite simple with no frills at all. I'll be using them for a program on the history of the banjo called BANJO AMERICA'S INSTRUMENT. They are used to teach large groups the basic frailing lick.

Here I'm sanding the Brazilian Rosewood for David's banjo.

Here it is sanded, not a good photo but...

Here one might think I substituted a bit of ebony!

And here the patterns are ready.

More soon...

Edited by - Dan Knowles on 01/30/2013 06:24:55

Dan Knowles - Posted - 01/30/2013:  06:27:24

You are so welcome David. This just seamed to be the proper choice for this project.

Ho C Ying - Posted - 01/30/2013:  06:35:09

I like small banjos!

Dave1climber - Posted - 01/30/2013:  06:43:55

Dan

For those that like small banjo, will they be available after the class is over?   Or will this be an on going learning project?

Dave

Dan Knowles - Posted - 01/30/2013:  20:04:46

C Ying

I like these piccolo (small) banjos. They have a very unique tone in the banjo world. I have used mine on several recordings and there are places where nothing else works.

Dave,

I'm thinking of making a limited number of these available beyond this bunch of piccolo's. Keep your eyes peeled!

Dan Knowles - Posted - 01/30/2013:  20:20:10

30th. DAY of 49 Days....

SHORT POST

I forgot to bring the SD card for the camera back to work until after lunch today. Needless to say I got no photos of the mornings work. But  the results will here in show...

I milled the Brazilian Rosewood for David Emery's neck and cut the fret slots so it would be ready for its gluing this afternoon.

Here I'm lining everything up so that I can drill for locator pins.

Clamped and drilling...

Gluing & clamping...

Clamped!

Here is the piece of fossil walrus ivory that I'll be using for both the nut (I used it in the layout) and the 5th. string pip. I love the tapioca look of this piece. Very little (if any) of the dark will be seen in the finished nut.

More soon...

Paul R - Posted - 01/30/2013:  21:38:42

Well, at least you had time for a bicycle ride! It finally got above freezing here, and it rained. And you ride steel, too. What make is it?

Small banjos are intriguing. I saw a pony banjo demo video of a Dobson - what a neat sound! I have a cheap Gretsch tenor that I play clawhammer on.That little thing is fun to play in spite of the narrow spacing (and the missing fifth string). Something about the size itself makes it a blast to play. I'm thinking of adding a "bump out" for a fifth string. Would that be heresy (ruin a banjo neck) or a "go for it" project?

I find banjos and bicycles have something in common - they're fun to tinker with, and they ease away stress and tension.

Can't wait to see those mini banjos! You must have quite the library of patterns and templates.

DEmery - Posted - 01/31/2013:  02:04:12

Good morning Dan. It seems I get up between 4-5 A.M. these days and am ready to go. Anyway..., it gives me time to see what you did yesterday in Paris. As for the Brazilian Rosewood; I see why you chose it from the fingerboard photo. I knows photos never show the detail but that wood on caps, strap, and fingerboard will make a big difference pulling all the colors together with the walnut ebonized stain and relic hardware. Hey..., I got to pick the stain from the blanks. Should I send an old penny for you to match the hardware finish? My guess is you have one around the shop. David E.         

Dan Knowles - Posted - 01/31/2013:  04:23:04

Paul,

It's an old Biancci that I have to keep after more than any I've ever owned. It's always going out of adjustment. I know that many people do the 'bump out' on tenor necks and in my early days I was guilty of doing the same, but at this point and time I feel that it is a mistake to do such. Make another neck and save the the old one. Someone else may desire to use it in the future. We are not just here for ourselves.

Good morning David,

I'm feeling quite excited by how this one is coming together. As to the penny issue. Could you send me 3 or 4 thousand so I could have one to choose from?

DEmery - Posted - 01/31/2013:  10:20:47

Dan I sent a large bag of pennies back with the blanks. That exhausted my supply. David E.

rubicon - Posted - 01/31/2013:  15:38:46

That  piece of rosewood made a fine finger board Dave and kudos to Dan on a fine job this banjo is going to be a beauty !!   

Dan Knowles - Posted - 01/31/2013:  20:08:37

David & Rubocon,

Thanks so much!

Dan Knowles - Posted - 01/31/2013:  20:26:16

THURSDAY....

One of todays projects was this neck resetting. It is a late 40's Martin who's neck has been reset at least once before. The reason for this reset is the action has gotten  his one will also require quite a bit of bridge repair also.

The pulling began by pulling out the 13 fret.

Then drilling a steam port.

Stickin' the needle in to introduce steam into the neck joint.

Introducing steam...

Heating the fingerboard extension so it can be freed.

Freeing it with a flat knife.

Yarning on it to get the joint to move...

And out she comes...

Lastly befor the guitar can be left to thoroughly dry the joint must be cleaned of glue. This is completed on both halves of the joint.

More soon....

Dave1climber - Posted - 02/01/2013:  09:36:33

Dan

That procedure makes it very clear that if the neck is not removed correctly a disaster awaits the person that doesn't know what they are doing.  I can tell that a great deal of skill and experience go into making it look so easy.

Edited by - Dave1climber on 02/01/2013 09:40:19

Dan Knowles - Posted - 02/01/2013:  10:43:33

Dave,

It certainly can be troublesome. If one gets in a hurry with the steaming the heel/ dovetail/ neck bloc  can be broken. Watching it transpire can be hair raising for the novice but in fact it is all a matter of steam softening the glue and a bit of clamp pressure. There is nothing like that satisfying little 'Ah" the joint makes when it finally decides to release.

Dave1climber - Posted - 02/01/2013:  11:22:57

Dan

I am very interested in seeing how this goes back together.

Dave

Steven M - Posted - 02/01/2013:  13:24:49

Wow, that was impressive Dan...

Is 'yarning' a real term or one you made up? If the latter then it needs to be made official immediately!

Dan Knowles - Posted - 02/01/2013:  19:54:51

Yarning is defined by the official Grandpa Bobby Bob Almost word book as "pushin', pullin' , stressin' & in general yarnin' on somthin'".

Dan Knowles - Posted - 02/01/2013:  20:17:11

February day One....

CONFESSION IS GOOD FOR THE SOUL...

Now don't y'all get in no hurry I'll admit stupidity when the time is ripe and not before! Just stick around! They (who ever 'they" are) say that the definition of a gentleman is a person who can play the banjo but doesn't. Perhaps a new one is in order ...

Here the David Emery banjo neck is coming out of clamps...

laying out the backstrap... again,,,

Cutting it out...

Power sanding...

And gluing the veneers....

Ok this is where confessing takes place...

David texted me and asked about where was the tunneled 5th? When was the tube going in? OH NO I said. Then went to work removing the fingerboard and installing the string tube.

The glue is softened by a heating blanket...

Apart!

The neck profile is laid out along with the tube location...

And the peghead layout...

The tube channel is routed...

More tomorrow...

Ho C Ying - Posted - 02/02/2013:  01:51:11

Very nice pictures.
I was wondering who is the photographer.

manomusic - Posted - 02/02/2013:  02:05:30

I've been following this topic with a lot of interest, great information Dan. It was a mystery to me how the back strap was formed, now I have some idea. Looking forward to the next installation, just wish you lived around the corner :)

Neil

BNJOMAKR - Posted - 02/02/2013:  04:34:57

quote:

---

Originally posted by manomusic

I've been following this topic with a lot of interest, great information Dan. It was a mystery to me how the back strap was formed, now I have some idea. Looking forward to the next installation, just wish you lived around the corner :)

Neil

---

 He does live around the corner.... a mighty big one for most of us. But because of BHO and his willingness to share, the corners of the world become

much smaller and  friends live much closer!

Dan Knowles - Posted - 02/02/2013:  05:32:13

C Ying,

I must lay claim to the fault there. I have an old  Kodak Easy Share camera that has a timer on it and a tripod. I'll see if I can get someone to make a photo of my rig with me working so you can see. It's really not difficult. I've done this enough that I just grab and go. My dad use to say that most things are a numbers game, it is true here. Most days I'll make between 50 & 100 photos and use maybe 10.

Neil & Marvin,

Thanks. I do find this thing amazing! Truly an international place this Hangout! In 4 short posts and we are one person from China (C Ying), one from Australia (Neil), one from North Carolina, USA (Marvin) and little ole' me in Paris, Tennessee USA. I remember when it was difficult to just make a phone call across the state, now this...Amazing.

Not only do we get to visit like this but because of this Hangout I've had visitors from England, Canada, Australia, Germany, Holland and from all across the USA. Simply Amazing!

dbrooks - Posted - 02/02/2013:  07:28:56

Dan, that Martin guitar reset really caught my attention.  I have had a 1956 00-17 since 1969 or so.  I had the neck reset 12-14 years ago, and I had no idea what was involved.

David

Dan Knowles - Posted - 02/02/2013:  10:45:46

David,

Yes and this is just the easy part...

banjeaux bob - Posted - 02/02/2013:  12:09:56

Dan,I see you use a lot of smaller pieces to lay up the neck.Is this to reduce waste?

Bob

Dan Knowles - Posted - 02/02/2013:  19:35:48

Bob,

That is correct and also for grain orientation. Also this is the style of neck lay up prefered by master Classical guitar builders

Dan Knowles - Posted - 02/02/2013:  19:43:42

C Ying,

This is in answer to your photo question. The pictures were made by my student Eric Cendejas... he really did a great job, they tell the whole story...

More tomorrow...

Dan Knowles - Posted - 02/03/2013:  06:14:23

OH NO I JUST REALIZED THAT I FORGOT SOME FOLKS THAT HELP ME DO THIS THING!!!!!

Producer: OHA YEAH

Director: OLE BLIN DOG

Sound Engineer: WHATA U. SAI

Makeup Artist: Butt Ugli

Wardrobe: EMPERORS NEW CLOTHS

lights: B. P YOU

1st. Grip: LETA U. GOH

2ed Grip: EYE NO HANDLE

Kentucky Colonel: Mark Holladay

Tylerb1 - Posted - 02/03/2013:  06:23:51

Just plan excellent, Dan your only do excellent work. Bob

Dan Knowles - Posted - 02/03/2013:  06:41:06

DAY 3 OF FEBRUARY

Today (being Sunday) I'm not goin' ta goh down to da shop! unless I have to... But here in the inneres of all banjer players intro-national I post the continuin' saga of the tunneled 5th. strang bein' rescued.

As I recall back when we left off I was routing  the fifth string tunnel slot or channel, what have you. Well I've this roll of copper tubing which I prefer, so I cut a short piece off to use for the tunnel.

Then finding the approiate drill bit I started drilling into the peghead...

Next I tied the two channels together and eased the transition with a round file....

Although I didn't get a good shot of it, I drilled into the face of the peghead exposing the earlier drilled hole. Here I'm trying the tubing for fit...

Starting the gluing.

After clamping the neck was put up to set up. Next I was off an running on setting up a Recording King (I think it's) RK-35.

This is a new one and although the set up is not bad, for a factory built instrument, it still needed twiking.

The Head was too loose and the action needed attention. Here the truss rod is being adjusted...

The nut slots deepened, these are almost never correct...

Done... it must sound alright because Sophie dog isn't howling. Ballad of Jed Clampet never sounded so good... well except when Earl played it!

mOrE sOoN.>.>.

Dan Knowles - Posted - 02/03/2013:  06:43:09

Thanks Bob...

And I forgot

Chief Student: BOB TYLER

R. Blakeslee Gilpin - Posted - 02/03/2013:  07:19:45

Dan - really enjoying this thread. I especially like seeing the sheer variety of projects you've got spinning simultaneously. It's really neat to see all these instruments being built, repaired, etc. Are these tunneled fifth string photos of Doug Emery's Dobson? Can't wait to see how you'll work out the slothead with the odd number of tuners. Greg Galbreath, Doc Huff, Jason Romero and Colin Vance have all done these and come up with slightly different solutions. Look forward to seeing yours! Thanks for taking the time to share all this with the Hangout.

DEmery - Posted - 02/03/2013:  17:56:24

Now Dan...there was no need for confession. I simply thought the tunneled 5th string tube was a trade secret and photos were omitted. Anyway, I am glad to see it got in place and we are on track. The rosewood is really pretty Dan. That is add some beautiful detail to this banjo. Thanks for unglueing the fingerboard and sneaking a tube in the neck. I don't know much about playing a 4 string and this does remedy the situation. David E.    

Woodturner - Posted - 02/04/2013:  06:49:34

I don't know why, but I thoroughly enjoy the fact that a master craftsman still makes a mistake and is also so willing to admit it and share the fix.  Dan tells me that the craft is all about having the confidence, ability, and desire to forge ahead and to enjoy the mistakes as part of the journey.  As a student of banjo and life, I accept those as one of Dan's many pearls of wisdom.  Thanks Dan, for being my teacher and my friend.

Dan Drabek - Posted - 02/04/2013:  07:37:01

quote:

---

Originally posted by Woodturner

Dan tells me that the craft is all about having the confidence, ability, and desire to forge ahead and to enjoy the mistakes as part of the journey. 

---

I've found that one of the reasons a seasoned craftsman has the confidence, ability and desire to forge ahead, is because they know there are no mistakes that can't be fixed. 

Of course, it's always better to avoid the mistakes and not have to fix them. :->

DD

Dave1climber - Posted - 02/04/2013:  10:38:47

A very skilled craftsman can repair any mistake, AND never repeat it whether its their's or someone else's mistake.

Dan Knowles - Posted - 02/04/2013:  19:50:16

R. Blakeslee,

The tuners arrived UPS today. So if I have the time in the next few days the secret of my approach will be out!

David..I too thought it was a trade secret! At least the English have been keeping it hidden since the 1890's

Denton,

Thank you, I am honored by your complement and trust....Working through a mistake is always interesting and informative for me... finding I've made one on the other hand...

Dan & Dave,

Fellers I'm in your corner... I do understand Thanks.

josephefortner - Posted - 02/04/2013:  22:03:45

I love this thread. Dan keep it coming.

Kaelri - Posted - 02/05/2013:  05:54:48

This thread is always bright spot in my day too.  I sure enjoy the reading/learning.

Ellen

Dan Knowles - Posted - 02/05/2013:  17:57:03

Joseph & Ellen,

Thank you so much!You brighten my day with your comments!

Dan Knowles - Posted - 02/05/2013:  18:06:44

Well tonight I posted a classified add for a special banjo of mine. She is Maggie, made from a dipper gourd. She is a real sweetie. The gourd was specially grown for me in the garden of the HOMEPLACE 1850's in the U.S. Forrest Service's LAND between the Lakes. These are a fun build! I figured that y'all might want to see some photos of this one.

Here's MAGGIE!

Be Back Real Soon...

Dan Drabek - Posted - 02/05/2013:  18:35:28

Dan, I think Earl Shankar played one of those when he recorded Foggy Mountain Raga. :->

DD

Dan Knowles - Posted - 02/05/2013:  18:45:35

TODAY, day 4 of FEBRUARY,

The other day I noticed that my stage Minstrel banjo's head was broken.  For me this head which had been on the banjo since 1998 or so breaking jus' braked mi hart! In truth I've suspected that it would break for some time. So it was not a shock.

This is a 14 inch minstrel so today I got out a medium thin goat skin and went to work.

First I removed the old head...

Then I wet the new one in the sink until it was pliable and then stuck it on top of the rim...

Then I did all the fussin to get it tucked under the tension hoop...

I'd been having fun experimenting with the walnut stain so next I went to town on this head too...

After maybe 20 or so coats (Hair drying after each) the color began to tickle my fancy...

So I slathered some stain on the inside too!

Here tiz...

My bud Bob Tyler came by to string his banjo. So I took a brake from head coloring...

On goes the Royal stamp!

Back soon!!!

Dan Knowles - Posted - 02/05/2013:  18:49:11

Dan, I do believe you are correct in this information about Earl Shankar... Ah what was that label he was on? Sitcar?

Dave1climber - Posted - 02/06/2013:  07:01:04

Dan

What is the round "extra" hole in the rim for?

Dan Knowles - Posted - 02/06/2013:  15:45:48

Dave,

It's a thumb or finger hole for banjo tricks. You can see it in action in this video....youtube.com/watch?feature=play...34cGyXk_M

I hope you enjoy it!

kwl - Posted - 02/06/2013:  16:09:28

Dan that was certainly an enjoyable video. What a wonderful way to play the banjo! Thanks for sharing it.