Dan Knowles - Posted - 03/01/2015:  19:06:23

John,

Yes the armrest could be silver plated. The nickel would not need to be removed as nickel is used as a base for the silver. I have plated over some raw brass but I don't like the result as well. It looks like it needs a few things done to it before plating. 

First it needs a through cleaning. Any and all gunk, funk,  oils and such need to be off of it.

Second everything needs to be smoothed and polished. With plating what you see is what you get. If there are any imperfections they will telegraph through the plating.

If you'd like me to make an attempt at plating I'd be most proud to.

steveh_2o - Posted - 03/01/2015:  19:07:53

Dan,

That dowel rod makes me think you may have a future in the high end duck call business. 

Great work!

Steve

jbalch - Posted - 03/01/2015:  19:08:09

Dan:

In the Rogers Drum book, it says that those highly-regarded hides were scraped by-hand to the ideal thickness.  It also said that the workers who scraped their high-grade skins were the most skilled (and highest paid) workers in the plant.

I'm confident yours will turn out GREAT!

I would like to know more about how you did it!

JB

Dan Knowles - Posted - 03/01/2015:  19:09:18

David,

Perhaps when your white oak guitar is complete we can do that! 

Oops, was I supposed to say that?

jbalch - Posted - 03/01/2015:  19:15:24

Dan:  Dave hid your secret project from me for a little while ... but it is hidden no more. 

jb

quote:

---

Originally posted by Dan Knowles

David,

Perhaps when your white oak guitar is complete we can do that! 

Oops, was I supposed to say that?

---

Edited by - jbalch on 03/01/2015 19:22:10

Dan Knowles - Posted - 03/01/2015:  19:22:09

Steve,

Does that indicate that I'm a quack?

John,

I used a very sharp card scraper, clamped the hide to a piece of plywood and started scraping. First I felt by hand for thickness inconsistencies, then I started checking with a long reach dial caliper. One can feel the head change in stiffness as it is worked. It really was fun. After both sides were scraped I power sanded it with 100 grit. I had to clean the disk quite often as it clogged quite quickly.  

Tomorrow I'll try and mount it and we will se how good a job I did. Maybe the boss will still let me be the highest paid worker in the place. 

Dave1climber - Posted - 03/02/2015:  08:45:55

A plan

Contact Dan

Drive to Paris

Visit with Dan

Drive home happy

Dan Knowles - Posted - 03/02/2015:  18:44:42

Dave,

Drop me a line and come on down!

Dave1climber - Posted - 03/02/2015:  19:05:47

quote:

---

Originally posted by Dan Knowles

Dave,

Drop me a line and come on down!

---

In the summertime.

Dan Knowles - Posted - 03/02/2015:  19:11:52

MONDAY

Back on the roof again today. There was just a tiny bit of dripping inside from last nights rain water so I got out the ole' 16 foot ladder and went upon the roof.

That reminds me of a James Taylor song UP ON THE ROOF!

I followed every rubber seam and inspected those things for any looseness. I found a couple of possible issues and patched them. You know it sure is hard to play banjo with fingers crossed....

Although I was not able to spend all the time doing important stuff today, I did make some progress on the project which has me aaht up, The Scarecrow banjo.

Being as I sprayed a two part finish yesterday, today I was able to wet sand and do the first buff. Tomorrow I'll give it its final buff.

One of the end pieces being wet sanded with 800 grit...

And the center piece...

Now on the wheel for the first buff...

The bracket band being put together...

Bracket nuts, J-hooks and all the rest of that stuff goes together...

Laying on its head, together...

I needed to drill for the 5th. string tuner. I've got a jig that holds it true and secure in the drill press...

Tonights tip: When reaming for the 5th. string tuner, leave the neck clamped in place, change the drill bit for the reamer, set the drill press to its slowest speed and ream away. This makes for a perfect reaming every time. If your jig is set up correctly the are no sideways or out of line tuners...

After drilling the 5th. string pip is check fitted...

More Tomorrow!!!

Dave1climber - Posted - 03/02/2015:  20:26:45

Dan

When I get to this stage of building I find it to be exciting, and I have to remain calm to get the job done correctly.  I expect for you it's "old hat", nerves of steel.

Will1717 - Posted - 03/02/2015:  22:40:05

John:

In a recent post you referred to a Rogers Drum book. Do you have any reference as to where this book can be purchased, who published the book etc? 

Bill Rickard

DEmery - Posted - 03/03/2015:  02:55:47

Dan another great banjo about to get buttoned up. Hey...I just picked up on the Oak Guitar project comments. As confessed...I had to share with John my mania that ends up with a 0, 000, and dreadnought. I look forward to the project and know it will be a fine piece. My first Knowles guitar after all the stuff you built for me over the years. David E.    

Dan Knowles - Posted - 03/03/2015:  04:52:49

Dave,

I find this part of thr build to be quite exciting. In my early days I figured out that if I got in a hurry at this point that I mess things up (not that I couldn't anyway!), so I just take my time and get her right.

Bill,

I hope John can find that book (article) , it's on the internet someplace. I looked but didn't find it.

David,

Thanks. I'm looking forward to this next build. As you already know we've picked out a fine old (Martin ca. 1959) top, some beautiful white oak  (that I've had for 10 years), milled it and awaiting its place in the que. 

GMB - Posted - 03/03/2015:  05:22:34

amazon.com/The-Rogers-Book-Rob...sp;  Maybe this is the book John was speaking of.   Cheers, Jerry

kwl - Posted - 03/03/2015:  05:27:51

I don't know if this is book John referenced, but it is what I found: amazon.com/The-Rogers-Book-Rob...888408049

Edited by - kwl on 03/03/2015 05:28:42

jbalch - Posted - 03/03/2015:  06:12:28

quote:

---

Originally posted by kwl

I don't know if this is book John referenced, but it is what I found: amazon.com/The-Rogers-Book-Rob...888408049

---

 This is the book I mentioned.  You can read some pages about the hide head operations using the "Look Inside" feature on Amazon.

DEmery - Posted - 03/05/2015:  03:11:50

Dan I know this is BHO but in the spirit of Luthier's Life that covers all things luthier in the Knowles empire; attached is the Martin spruce top from 1959 that will go on the guitar. It will be an interesting piece and my first guitar from your shop. Let me know when it is coming up on queue and I will be watching closely. If you do test fuming the finish - it might be an interesting thing to see regardless of anyone's build of choice. David E.

Edited by - DEmery on 03/05/2015 03:12:59

Dan Knowles - Posted - 03/05/2015:  17:47:05

David,

That top is from a group of tops (about 250 sets) that I bought from retired Washington D.C. Luthier Tom Morgan about 15 years ago. Now Tom lives over in Dayton, Tennessee (site of the famed "Scopes Monkey Trial).  Tom bought these from Martin Guitar Co. in 1960 which means that they were probably milled in 1959. Tom bought a pallet of these and when he offered them to me I went and embarrassed my bank account and bought all that he had.

These are wonderful guitar building wood. They are perfectly aged, 56 years old. Like me the resins are now aged solid! The color is amazing. When finished the tops look old and sound old. I've built a bunch of guitars from these tops and they never disappoint me.

Dan Knowles - Posted - 03/05/2015:  18:19:33

THURSDAY

Welcome to the Sweet Sunny South!!!

8 inches of snow in one night. It started raining ice last night around 6 and then around 9 pm it started snowing. When I got up this morning it was still snowing. How bout that, March fifth and down comes one of the biggest snows we've had in years.

Being more than a bit foolish I tried to drive in to work... got stuck! Patrick and I dug the van out, I got it back to its parking place and walked to work.

I do like the kind of snow we usually get here in the winter, snow for just a few days and then it's gone!

That's the ole' Knowles manse there in the middle of the photo with the green gable... but where is Anne?

After I walked to work in the snow, I poked the Scarecrow together. There are a bunch of photos here. I do hope you enjoy them!

In with the coordinator rod...

And neck...

Drilling for the tuner pins...

Installing the tuning machines...

Installing the fifth string tuner...

Laying out and cutting the nut...

Preparing to install the strings

Strings on I got this "glamor" shot of the tailpiece...

First stringing. There will be a bunch of work yet to come perfecting the set up and such...

On goes the tag. I redesigned my tag a bit today (yes David I did again!). The steamboat picture is now sepia toned. Perhaps I'll use this version on banjo's as it is for a while!

On!

I'll finish the set up in the morning and hopefully I'll be able to shoot some good photos of the Scarecrow and post them tomorrow. I  don't think, though, that I'll make any sound files of this instrument. I'll bet Tyler  will do that so ably himself!

MORE TOMORROW!!!

Nels - Posted - 03/05/2015:  18:47:16

That is one pretty banjo! ....with all that snow and ice I hope your roof has stopped it's 'nonsense'!! stay warm...

dbrooks - Posted - 03/05/2015:  18:58:22

Another beautiful banjo, Dan. Just stunning in the fresh design and detailed execution. Thank you for sharing this journey (and the other journeys) with us. 

David B. 

Will1717 - Posted - 03/05/2015:  19:11:53

Dan:

Looks like you've outdone yourself one more time! This is one beautiful banjo to say the least. I'm interested in how you modified the bracket band to bring the band down under the complete heel profile. Did you braze in a piece of brass to get this profile? One thing I've always disliked about the standard Vega style band is the fact that you need to fit the base of the neck heel over the lower edge of the band,  to fit against the lower rim profile. Your solution looks like a perfect alternative to my eye. It just looks like it should be this way! The silver plating is also a real winner on this build. Beautiful job that I'm certain Tyler is going to be over the top with.

I didn't realize that you actually got snow in your part of the world. If you need anymore just let us know, as we have more than our share this winter!

Bill Rickard 

Dan Knowles - Posted - 03/05/2015:  19:41:15

Nels,

Thanks! This snow will certainly test it, that's for sure!

David,

Thanks!

Bill,

Yes I brazed a chunk of brass to the bottom and then shaped it, I've never liked the looks of the Vega approach either.

Yes, we do get snow. This is the second time in three weeks!

Kaelri - Posted - 03/05/2015:  19:50:40

Wow, Dan! I must say Paris is looking quite a bit like Michigan! I can loan you a sled if you like. 

And Tyler's banjo sure is looking mighty fine!

Paul R - Posted - 03/05/2015:  21:01:09

Super banjo, Dan. The engraving is like icing on the cake.

Looks like a bit of snow*, too. It sure makes for a pretty picture, but where are the cross-country skis? (Or maybe you can commute on skates, like some people do up in Ottawa, on the Rideau Canal. You could even stop for a Beaver Tail.)

* That's a nice little dusting. We can send more. 

 

Dan Knowles - Posted - 03/05/2015:  21:47:47

Ellen,

Thanks! I wish I had a sled I'd be out playin' in this stuff!

Paul,

Thanks!!! That commuting by skate sure looks like fun. I have no skies, skates or sleds  either so I guess I'll just have to let you keep your snow and we'll try and to get rid of ours...

BTW, I just looked up a Beavertails recipe, those look real good. I may try to make some one of these days.

Edited by - Dan Knowles on 03/05/2015 21:53:11

tylerandal - Posted - 03/05/2015:  22:38:05

Oh...  Tomorrow's gonna be a big day!!!

rubicon - Posted - 03/05/2015:  23:28:08

quote:

---

Originally posted by tylerandal

Oh...  Tomorrow's gonna be a big day!!!

---

DEmery - Posted - 03/06/2015:  03:29:32

Dan I like the builder label on your banjos. I have one but it was different on banjos you built for me prior to St. Augustine. Did you use it on banjos before Augustine? David E.

 

Dan Knowles - Posted - 03/06/2015:  05:02:40

Tyler & Rubicon,

Today is a big day!

David,

Over the years I've used a bunch of different labels. I remember you remarking once about how they always seams to be different banjo to banjo. The label on St. Augustine is a basic design that I've used for several years. I have a banjo in the shop now (for a set up) that is  a couple of years older than yours, it has this type of label. As a bit of a side note, this is not the label that I use on other instruments.

guitarman8491 - Posted - 03/06/2015:  05:20:37

Dan..the banjo is magnificent..you are a true artist!

Dave1climber - Posted - 03/06/2015:  06:58:42

Dan

I see a lot of banjos at Elderly Instruments, none of them are as good looking and as tastefully done as Tyler's banjo.  Very well done!!

 

 

Ross - Posted - 03/06/2015:  08:33:29

Stunning!

Dan Knowles - Posted - 03/06/2015:  16:27:37

Doug, Dave and Ross,

Thank you so much! Tyler is on his way to Paris from Nashville even as I pen this post. So here is what he will see after a bit....

THE GLAMOR SHOTS

of the

SCARECROW & the SHIPWRECK

MORE SOON!!!

Dave1climber - Posted - 03/06/2015:  16:45:09

Absolutely fabulous.     Makes me wish I was there to see Tyler's reaction to that work of art.  Please let us in on his reaction.

guitarman8491 - Posted - 03/06/2015:  16:55:47

I have to agree with Dave..Stunning one of a kind instrument. I have a feeling Tyler will never look at another banjo! Dan you are truly an artist !

rubicon - Posted - 03/06/2015:  17:54:08

Thats an incredible build Dan Tyler will be blown away art·istˈärdəst/nounnoun: artist; plural noun: artistsa person who produces paintings or drawings as a profession or hobby.synonyms:designer, creator, originator, producer; old master"a mural artist"a person who practices any of the various creative arts, such as a sculptor, novelist, poet, or filmmaker.a person skilled at a particular task or occupation."a surgeon who is an artist with the scalpel"synonyms:expert, master, maestro, past master, virtuoso, genius; Moreantonyms:novicea performer, such as a singer, actor, or dancer.informal
Dan Knowles

DEmery - Posted - 03/06/2015:  19:31:43

Another great piece out of Knowles Stringed Instruments in Paris, Tennessee. David E.

rubicon - Posted - 03/06/2015:  19:41:59

Tyler please hook us up with a you tube sound sample would really like to hear this banjo..

Dan Knowles - Posted - 03/06/2015:  20:02:32

DAVE,

THANKS!!! You asked for it look below!

Doug, Rubicon & David,

Thank you so much.

BTW Tyler let me know that I forgot to post a photo of the peghead... I'll do that tomorrow, I've a nice photo on the computer at work.

Dan Knowles - Posted - 03/06/2015:  20:13:57

ELVIS HAS LEFT THE HOUSE!

The Scarecrow, Tylers momma Joy & Tyler have just left heading back to Nashville.

What a nice visit we had. Joy, my wife Debbie and I yick yacked to a background of some of the finest banjo playin' I've heard in a long time. Not much talkin' out of that feller, just a lot of wonderful banjo music.

I think Tyler liked it. But I guess we'll have to wait and see what he has to say!

Perhaps he'll even make a video!

Here is the first time he picked up and really looked at his new banjo...

All three of us are here!

See ya tomorrow!!!

manomusic - Posted - 03/06/2015:  22:46:43

That is an incredible work of art Dan, you put so much into your banjos. What do you use as a finish Dan? It looks perfect!

All the best,
Neil

manomusic - Posted - 03/06/2015:  23:06:36

Sorry Dan,

I should have payed more attention to your earlier posts!! I've just read about the 2 part finish and how you apply it thankyou.

tylerandal - Posted - 03/06/2015:  23:29:08

Hi all!  I've been playing the banjo for a few hours now.  It sounds great and is breaking in and changing tones really quickly!  I'll post a video soon... I'll have to think of something good though.  

Also Dan, the adjustable dowel rod works incredibly well!  There was a tiny little buzz on the low D string and without thinking about what I was doing, tightened the rod just a little.  It instantly fixed the buzz!  It's super handy the way you made it.

Anyway, I'll also include a photo of the headstock and just another from when I was trying to politely remove the banjo from Dan's hands earlier :)  

dan

Yanni - Posted - 03/07/2015:  00:44:02

Totally beautiful.  I can't wait to hear it :)

Ian

Nels - Posted - 03/07/2015:  03:44:40

I'll just add 'Wow' to the above compliments and now we wait for the vid and sound!!  ..... 

Dan Knowles - Posted - 03/07/2015:  04:07:32

Neil,

Thanks! I know you figured this out but here is basically how that finish is achieved.

First it was sanded to 800 grit, then stained with a mixture of natural (shop made) walnut stain & metal dye (vinegar & steel wool). 

Second a very thin coat or two of shellac as a sealer and to make the grain 'pop'.

Third, sprayed with a catalyzed varnish, allowed to cure. This is not a finish to be sprayed without protection (ie. spray booth & respirator).

Lastly wet sanded to 1200 then buffed using McGuier's compounds.

In the shop I use several finishes including: Spirit Varnish, Violin Oil Varnish, Oil, Lacquer and Catalyzed  (2 part)) Varnish. It all depends on what the person I'm building for needs & wishes.

Tyler,

I am so happy you are enjoying the Scarecrow and the Shipwreck! It is amazing to see/ hear how much they change in those first few days and hours.  We (and especially me) are looking forward to hearing some amazing things from that instrument (no pressure here!)

As always it was great to see your mom and you. You are so much like family!

Ian,

Thank you so much!

Nels,

Thank you too!

Edited by - Dan Knowles on 03/07/2015 04:08:38

guitarman8491 - Posted - 03/07/2015:  05:08:06

Tyler..congrats on having one of the finest banjos on the planet! Can't wait to hear a sound clip of you playing it.