tylerandal - Posted - 01/23/2015:  18:25:27

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What are your thoughts on banjo heads for this guy?  The hardware is gonna end up being silver, right?  Some of my friends have talked about trying to get a black head on it...  and I'm assuming the ones you can buy are probably not as good.  I think silver and black could look cool, but not necessary if it's a hassle or won't sound good.  I'm just curious what you think :)

Also, heard a bit of the string section for Wings today... They are sounding great!

Dan Knowles - Posted - 01/23/2015:  20:26:16

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Jon,

You are very welcome! It's another good one!

Tyler,

Yes Tyler, the plan at present is for all of the hardware to be nickel plated... but a black head... I've been planning on using a Fiberskin on this one. I maybe could stain it black or if you'd like a goat or calf skin head (I think could dye that back). If we go in that direction I think that we should just go all the way and I'll patina all of the hardware black or nearly so. That could be a very visually striking instrument.

Dan Knowles - Posted - 01/23/2015:  21:01:46

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FRIDAY

Debbie and I just returned home from a wonderful evening out with our neighbors Fiona & Jim Jackson. They live across the street in the antebellum house. We went over to Martin, Tennessee to have dinner at the Opera House restaurant. The food was great and the service superb. But there was no opera nor even Opry there at all!

I milled the ends of Tyler's frets today. I've got a Stu Mac bloc with a file set at an angle in it. Usually folks hold the neck still and file from the top. I've found it easier for me, to clamp the tool in my vice and run the neck on top. 

Next I made the truss rod cover. I found some old and very thin tortoise shell veneer that I bought at an antique store years ago, glued it to a thin piece of ebony and cut out the basic shape on the band saw...

...Laid it on the peghead to figure size...

... milled it to shape. Then laid out that shape on the peghead. And then routed an area for it to fit down into...

After everything was fit I installed a magnet (in the peghead) and glued a small piece of shim stock to the underside of the truss rod cover. Now it will stay put. Look ma, no screws!

I'm building up a new set of molds for the guitars that I'll be building.

First a pattern was cut from MDF. It was sanded until it was just perfect. This was then used to lay out the other pieces which will make up the molds. These pieces were band sawed out...

...then trued on the router table...

Here is the stack ready for gluing. Using dowels for indexing the glued together wonderfully. Unfortunately I forgot to shoot any photos of them under clamps so I hope you'll let me get away with this photo of the pieces ready for gluing and clamping!

More Tomorrow!

bornold - Posted - 01/23/2015:  21:28:19

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Nice. Like the new avatar btw!

Dave1climber - Posted - 01/23/2015:  21:38:47

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Another busy, productive day!   Organization and energy!

DEmery - Posted - 01/24/2015:  03:14:43

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Off into guitar building; hey Dan? What size guitars will they be and how will they be different? David E. 

Dan Knowles - Posted - 01/24/2015:  04:57:58

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Canaan,

Thanks.

Dave,

Well to be honest I didn't get as much done yesterday as I would have liked...

David,

There are two 000 size and one 00 size. Two will have slotheads and one will be a paddlehead. 

Dave1climber - Posted - 01/24/2015:  07:07:37

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Dan

I also often don't get as much done as I would like, however I always read this thread.

guitarman8491 - Posted - 01/24/2015:  08:31:22

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Dan..great looking Banjo neck..love the peg head overlay and the magnetic truss rod cover. Very ingenious!

Dan Knowles - Posted - 01/24/2015:  14:29:36

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SATURDAY

I just got done eating a bit of soup after coming home from the shop. This being Saturday I'm home a few hours earlier than I would normally. Debbie tried to install TURBO TAX on our shop computer and something went awry. It won't let us un-install the program. An error message keeps popping up. So now I have the thing de-fragging and I'll try to un-install then re-install.

It was very successful today during the Lutherie class. Kevin got way into his guitar body binding. Zeb glued in his end blocks and installed his lining...

...and I prepared to do a video on top choosing and braced a guitar top...

Zeb sticking on one last clamp...

And my top, under the go-bar deck, part way into gluing...

Here almost complete...

See Ya Soon!!!

 

DEmery - Posted - 01/24/2015:  16:53:25

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Dan I have never seen so much stick wood bracing a guitar top. What sort of contraption is that? David E.

Dan Knowles - Posted - 01/24/2015:  17:32:00

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David,

That contraption is a go-bar deck. All of those sticks exert pressure holding the braces in place as the glue sets up. The only thing much better would be vacuum gluing, which I do not have. I've never used the go-bar in banjo building. I suppose that if I cogitate on it long enough I can figure out something to use it on!

DEmery - Posted - 01/24/2015:  18:54:24

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I had to get a closer look and found this image that shows the whole set up. I see. Interesting. David E.

 

tylerandal - Posted - 01/24/2015:  22:11:26

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Woah!  You knew I'd like that truss rod cover ;)

I would love nickel plating, i didn't want to change that.  I was just curious about the black on silver look...  kind of like a fiddle bow would have.  But it was just a quick idea.  I'd be fine with anything.  

I can't wait to play some more!

 

Dan Knowles - Posted - 01/25/2015:  06:09:35

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David,

I have a bunch of rods or batons of different  length. They are used depending on what I'm gluing. Longer rods (like these) for tops & backs and shorter ones for gluing tops or backs to the ribs. I may go to the shop today for an hour or two and carve those braces. And then I may not.

Tyler,

I knew that I needed to sneak a bit of tortoise shell look on to this banjo some where. Originally I was going to make the cover of just plain ebony, but...

The black head, I'm still thinking about that. I'll dye a head soon and see how it does. What I ought to do is paint you a head, with dots! 

Will1717 - Posted - 01/25/2015:  06:59:41

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Dan:

I'm also in the process of building up a couple of acoustic guitars and am in the process of building a Go-Bar clamping system to assist in the glue up process. I'm assuming that your using a radiused disc under the top as you glue in the braces. Is this accurate and if so what radius do you usually use for the top and back bracing? It's also interesting that you don't do any preliminary brace shaping prior to the glue up process. Is there a reason for this? I use to build guitars many years ago (approx. 50 years ago actually) and never used a Go-Bar clamping system in the past, so this is all new to me. Being that I'm working one handed, I'm hoping that the G0-Bar system will make the process easier. Hopefully it will do the job with minimal frustration! Any advice would be appreciated Dan.

Bill Rickard 

Dan Knowles - Posted - 01/25/2015:  07:36:52

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Bill,

You are quite correct in that I do use radius dishes for brace gluing. 25' for the top and 15' for the back. For top & back gluing (on a guitar like instrument) the go-bar deck is the way to go!  Because I like listening to the top as I shape the braces they are never shaped before hand.

For one handed clamping this or a vacuum system would be defiantly the way to go. It would be easy to install the batons that way.

You might try the go-bar deck as a brace shaping clamp system (if you shape the braces later). I may even try it one handed on this top when I go to carving the braces. I'll let you now how it goes. 

cbcarlisle - Posted - 01/25/2015:  10:21:05

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Thread parenthesis: It just dawned on me (as I noticed this is page 127), I pity anyone just discovering this thread. They will have one heck-of-an-all-nighter trying to catch up. Even the rest of us have to hold on tight to keep from getting left behind. I won't ask you to slow down, Dan, but this is intense stuff! (Of course I wouldn't have it any other way.)

Dan Knowles - Posted - 01/25/2015:  17:27:41

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Curt,

It is 127 pages now...

Thanks for coming along for the ride!

Kaelri - Posted - 01/25/2015:  17:36:24

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Just popped in to catch up the latest here and could not help but notice the view count was exactly 220,660 when I got ready to "open the door"! 

Dan Knowles - Posted - 01/25/2015:  17:59:26

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Sunday

I've hardly left the homeplace today. Mostly I stayed put and worked around the house.

I did go to Lowe's (to give stuff back) and to Sam Walton's place (to bring some stuff home). Mostly though, I spent the day with my wife Debbie. She crocheting and me painting on the PUPPET MASTER. So tonight I have a bit of an update on that work.

This painting is about 7 &1/2 feet tall. Other than some undercoatings it has been painted in a Pointillist style. Most of it has been accomplished with a tiny 18/0 or 3/0 round brush.  Here is a photo to prove just how crazy one person can be , making something this big with such a small dot technique...

Among this weeks major changes (and major to me might not be major to you but they are major to me. How's that for a convoluted sentence!) are in these next few photos.

The Sandwich Sign Guy's sandwich mirror sign was completed this week. When I get up to my left handed banjo picker I'll do a bit more work to make his face clearer and I soon finish up Sandwich Sign Guy's right hand...

My painter of the puppets face and hair were painted...

And my Blue Lady's features were softened and she received a batch of earrings. Now she looks just the way I had pictured her in my mind...

Here is how the painting appeared just before I shut the lights off in the living room...

MORE SOON!!!

 

Dan Knowles - Posted - 01/25/2015:  18:02:10

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Ellen,

Come back! Please come back! Really, really, really, I really was a-workin' on the post when you posted! Sorry I missed you!

Kaelri - Posted - 01/25/2015:  18:03:09

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Nels - Posted - 01/25/2015:  18:16:33

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Wow..watching a banjo come together over time and your painting, all on one wonderful channel! Ahh, to be a fly on the wall in your shop. 

Dave1climber - Posted - 01/25/2015:  18:34:58

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Dan, painter of the puppets!   Looking good.

DEmery - Posted - 01/25/2015:  18:39:03

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Dan...where does one put a 7 1/2' puppet master painting? David E.

rubicon - Posted - 01/25/2015:  18:43:40

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I had no idea that painting was that big you must have some serious wall space in your home.

rubicon - Posted - 01/25/2015:  18:48:49

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I had no idea that painting was that big you must have some serious wall space in your home. it amazes me what you accomplish in a week you never stop going ....building, fixing,repairing, painting, drawing, writing,photographing, playing on the riverboat teaching, roasting coffee beans lol holy mackrel do you sleep ???

Dan Knowles - Posted - 01/26/2015:  10:39:26

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Nels & Dave,

Thanks!

David & Rubicon,

The walls in our old home are 11' tall. I'm thankful as it has enabled me to move the thing up so I don't have to bend down so much. It's better on my poor ole back.

As to sleep, I do sleep at night... sometimes...

60spicker - Posted - 01/26/2015:  11:19:33

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I note, as others have, that the painter figure bears a wonderful likeness of one Dan Knowles, complete with s***-eating grin (please. no offense).

Dave1climber - Posted - 01/26/2015:  11:21:18

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Dan

When you bother to sleep, you must have some wonderful dreams!!  

60spicker - Posted - 01/26/2015:  11:36:30

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I'm also smiling at the people who are marveling at your artwork talents and at the size of Puppet Master. Everybody on this forum needs to visit Paris, Tennessee sometime and beg you to visit your home. I've said before, your gifts are staggering and deep, and I wish everyone to know that. Your paintings will, honestly, be worth a fortune some day. If people haven't seen the video you made a few weeks back, here it is again:

I envision Antiques Roadshow circa 2115, where somebody brings Puppet Master with them, and the hosts just go nuts, and call it "Knowles most impressive work" and proclaim the value to be in the millions. Hey, a guy can dream, right?

guitarman8491 - Posted - 01/26/2015:  12:35:45

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Dan.. your work is very special..your talents are many and you share them with us with such humbleness..thank you!

DEmery - Posted - 01/26/2015:  14:54:00

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Dan I don't have anything else to offer today but since this should be my 1,000th post; I wanted to put it on your thread. Only took a decade to reach. Most have been about something you did for me while building banjos or making some comment about Puppet Masters, etc. David E

Dan Knowles - Posted - 01/26/2015:  17:11:38

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Terry (twice),

Thanks so much. It sure was nice to have you in our home a few weeks ago. We hope you'll come back soon!

Oh and Terry, I never tell folks who my models are!

Dave,

It's those crazy dreams that keep me awake at night!

Doug,

Thanks! I'm just thankful for all you kind folks and a place that I call home.

David,

Congratulations!!! And thanks for doing it here! 

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Edited by - Dan Knowles on 01/26/2015 17:12:54

Dan Knowles - Posted - 01/26/2015:  17:47:41

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MONDAY

First of all tonight's disclaimer...

Bill,

I tried to do some brace shaving using the go-bar deck this morning, for me it just didn't work. I felt too constrained by its upright posts. I did do some one handed (with a hand held behind my back, although I got no good photos) and I think that if I needed to do it that way, I could. So I am sure that you could also.

I'm sure that there are better and easier ways of doing this, but this is how I shape the braces. The top is clamped into the radius form.

One of my great-grandfather's chisels has a rounded profile. This one is kept razor sharp and off I go chiseling.

The side profile is shaped with one of these small planes. The little box plane is my newest. It was given to me by my student Kevin Bailey. It came from Harbor Freight. They are sold in packs of three and this one properly sharpened is a dandy!

After shaping I sand them to 220. 

Bet you thought I had become an apostate with all this guitar stuff. 

It's

BANJO TYME!

Back on Tyler's neck, it was sanded to 400.

Then some of the HOME BREW walnut stain was applied. This stuff works wonderfully but boy is it getting ripe! What a stink!

Next my metal stain is applied. This neck is getting the same treatment as St. Augustine and Shine.

After a couple of minutes the metal stain reacts with the tannins in the walnut ad really richens up. Tomorrow I'll sand & stain it again. Then hopefully Wednesday it will find its way into the spray booth.

MORE TOMORROW!!!

 

 

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Edited by - Dan Knowles on 01/26/2015 17:50:02

rubicon - Posted - 01/26/2015:  19:12:55

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Coming good Dan what are you putting it in the spray booth for ? is the finish different than the lovingly hand rubbed St.Augustine .?

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Edited by - rubicon on 01/26/2015 19:14:13

Pine Cone - Posted - 01/26/2015:  20:38:29

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Shine's neck is the nicest of any banjo I have ever played.  Beautiful, great finish, great feel while playing, and with a wonderful heel carving.  I'm sure Tyler is getting antsy waiting for it to all come together.  Shine is known as my "pretty banjo" by the people I play with.

David - Congrats on your 1000th post.  I'm not sure I would have had Dan build Shine if I hadn't watched St. Augustine get built here in Dan's thread.

 

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Edited by - Pine Cone on 01/26/2015 20:44:20

tylerandal - Posted - 01/26/2015:  23:06:05

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Scott,

I agree that shine's neck was amazing!  I got to see it right as it was getting finished up.  That's why when Dan asked what kind of maple I wanted, I asked for something as similar to that maple as we could find.  :)

I've had a lot of fun lately just playing my old banjo a lot.  I really can't wait to get a Knowles banjo that I've waited my whole life for though.  The more I play the one I have now, the more it makes me want the Knowles...  I keep hearing about a show coming up on feb 21 that might be a good night to come hear the banjo, I hope :)

 

Dan, 

The color looks incredible!  I can't wait to see it after the next coat!

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Edited by - tylerandal on 01/26/2015 23:06:31

Dan Knowles - Posted - 01/27/2015:  05:51:12

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Rubicon,

Yes this will be different than the oil finish on St. Augustine or Shine. I do many types of finish here in my shop. Spirit varnish, oil varnish, rubbed oil (gun stock finish), lacquer and two part poly.

I suppose this is one of the upsides of working with a luthier for a custom instrument. Tyler asked for more shine and flash for his banjo. So instead  of oil it will be a sprayed lacquer finish.

Scott,

Thanks so much. 

Tyler,

If all continues to come together as it has so far, I plan to hear and watch you play the Scarecrow on stage at Lee Academy. Here is the first poster for that concert:

Crusty - Posted - 01/27/2015:  06:30:29

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Hey Dan, since you're a fan of finishes (FoF?) I'm wondering if you've ever tried anhydrous ammonia staining?  I've seen it used on quarter sawn oak furniture and it really brings out the rays in that wood, and it used to be fairly common in original craftsman style furniture.  If you've ever seen a piece of oak with very visible and striking appearing rays in it then it was likely ammonia treated. 

Essentially the wood is exposed to ammonia vapors for a period of time (a day or more even) and the wood changes color where the ammonia reacts with the tannins in the wood, turns darker and takes on a striking silvery cast. 

The method's typically been used only on oak because of it's higher tannin content, but I've lately become aware that liquid tannin can be purchased, which could be brushed onto any wood and then reacted with ammonia, and I'm thinking that staining technique might look really unique and beautiful on figured maple.

Dan Knowles - Posted - 01/27/2015:  18:03:34

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Mike,

Interesting that you should ask about fuming. I recently took in an order for a white oak guitar. The guitar is to be colored by fuming. I've never fumed maple. In essence the way this banjo has been colored is by chemically effecting the tannin (in the walnut stain) with the metal stain (vinegar & steel wool). This is what gives the depth of tint here on Tyler's neck. Sometime I'll have to try this on maple and other woods.

Crusty - Posted - 01/27/2015:  18:32:53

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I read a bit more about it today Dan and first of all anhydrous ammonia is far too concentrated and a bit on the dangerous side.  Grocery store ammonia will work but it takes a long time because it's so weak.  If you can find some at the hardware store in the 20-30% range it should work just fine.  You can also speed the reaction by putting a candle under the tin of ammonia to warm it.

I also learned that making a strong dark tea and painting it on introduces tannin into wood.

All the info I found about fuming today urges the user to do tests on scraps of the same wood before exposing the work piece.  It's pretty straight forward - the longer the wood's exposed the darker it gets, and rather than being a colorant on the wood, it induces color change in the wood that isn't much affected by subsequent sanding, so if it's too dark then it's going to stay too dark.

I even read a story about the interior of a bank finished in oak which was too light for the owners tastes, and with the grand opening only a couple of days away the contractor sealed the building and put out tins of ammonia with candles under them and left it that way for a while and it was darkened to the owner's satisfaction by opening day.

I also learned about the steel wool and vinegar (or acetic acid) stain for maple today too and it seems to be the recommended stain for that wood.

Dan Knowles - Posted - 01/27/2015:  18:34:07

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TUESDAY

1-27-2015

Tonight I'll let the photos tell the story.

Continuing from yesterday's work on the Scarecrow & the Shipwreck banjo first off I buffed the neck clean of dried residue...

Then the neck was sanded with 400 grit to be rid of any raised grain and to make the curl more visually pronounced...

Then it was given more stain...

Here is the neck along with its sister parts, the rim and dowel stick...

Here with a thin coat of spirit varnish...

MORE REAL SOON!!!

 

 

Dan Knowles - Posted - 01/27/2015:  18:53:05

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Mike,

Thanks that is some great research!

Paul R - Posted - 01/27/2015:  21:22:23

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That's a fantastic, seamless shape to that neck, Dan. It flows flawlessly from peghead to heel. Dad used to say, "That house has nice lines." Well, that neck has nice lines!

Seeing your tall painting brought back memories of heading downtown in Toronto to the Art Gallery of Ontario on a hot summer day to bask in the glow of the huge Group of Seven Paintings - different style (and subject), but same feeling of having the art wash over you.

DEmery - Posted - 01/28/2015:  03:23:28

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Dan that walnut elixir sure makes maple look nice and in particular on that grade of maple. The finish will really pop the curl since gloss is preferred on this banjo. Interesting chat about "fuming" oak. I hope you show some of the photos of that oak guitar when it comes time to fume it. I am familiar with old oak furniture and the pretty figure. Stickley Furniture was in many hotels I stayed at in New York. Pretty stuff. If oak makes a good tone wood - that should be nice. David E.

Dan Knowles - Posted - 01/28/2015:  05:07:41

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Paul,

Thanks so much!

David,

This will be an interesting build and I'm sure I post at least a bit of it.

guitarman8491 - Posted - 01/28/2015:  08:00:20

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What a wonderful looking banjo..amazing craftsmanship!