Dan Knowles - Posted - 02/16/2013:  19:10:08

Actually Dan,

   that was taken in the parking lot of Lee Academy for the Arts... it was easy for this "BAbner" to find...

David,

I'm glad you like them. They've been a bunch of work but it feel good.

Rubicon,

Thanks.

Dave1climber - Posted - 02/16/2013:  19:47:53

Dan

I would think that if I had those tuners in my hand, I would not be able to tell which end had been cut.  Looking good.  

R. Blakeslee Gilpin - Posted - 02/17/2013:  05:21:56

Dan - incredible job on those tuners. That's the idea that's always been in my head to match the originals and your skills and ingenuity made it happen. Awesome!

Dan Knowles - Posted - 02/17/2013:  05:28:14

Dave, & R Blakeslee,

Thanks. Those were a lot of work. Thankfully my Canadian friend Bill Rickard is working even harder to create some tuners. They will be both high quality and made for banjos. I had hoped a set might be ready for this instrument, but they are still a while off.

R. Blakeslee Gilpin - Posted - 02/17/2013:  05:37:38

But Dan, Bill surely isn't making them for that rare beast - the tunneled slothead - is he? Very cool that he's going down the slothead road...

Dan Knowles - Posted - 02/17/2013:  05:49:27

KETCH-UP cont....

I believe it was Dave 1 Climber (if my memory is right) who asked sometime ago, about how I cut/ form banjo heels. Well yesterday I did two and this is how I did it.

Usually I only use straight sided banjo rims. I can and on occasion do Gibson style rims and that requires a whole different approach. This is how I've jiggedd up over the years to do this job.

First the heel is basically cut on the bandsaw. I use this fixture to hold the neck at the correct angle. There is a mating fixture on the saw to cut the curvature. The neck is shimmed and clamped in place.

On the saw

Next I mark the Tension hoop relief and cut the basic part out on the table saw. The tall fence is a requisite item.

Cut...

Next because this tablesaw is an 8 inch saw (I use 7 1/4" blades) there is a bit of extra material that needs trimming. A chisel does the job quickly.

Now on to this jig to further refine the heel...

Two necks and the heel shaping fixture...

More soon...

Dan Knowles - Posted - 02/17/2013:  05:51:03

R. Blakeslee,

I believe he will be making both.

DEmery - Posted - 02/17/2013:  07:04:19

Taking shape Dan. It shouldn't be long until you get the spoke shave out and rim er' down. I know you have some photos and drawings for the profile. If you want to talk before we carve; let me know. David E.

Dave1climber - Posted - 02/17/2013:  08:47:40

Dan

It was me that wanted to see how you do heel cuts. Thanks for showing us how you do it.  Your jig for doing it is simple, the best ideas always are.  PROGRESS !!    I thought that doing the heel cut is a very critcal parts of banjo building, you make it look easy.

Dan Knowles - Posted - 02/18/2013:  05:28:56

David,

This morning time allowing, I'm planning on mortising the necks for the dowelsticks and profiling each of them. Next I rour and install bindings. Then on to the carving. I hope to be there by Saturday. And yes Ido hope we talk before that date,

Dave,

I'm sure that there are easier and quicker ways of achieving this. Mine is simply how I've developed over the years. Of recent days I've been effected by Luthiers (big L) here on the hangout.. Folks like Bill Rickard and many, many others.

Dan Knowles - Posted - 02/19/2013:  20:27:05

19 February 2013

2 count 'um 2 very busy days. Now it's 10:07 and I 'm just getting to the BanjoHangout post. Whew! I'll see if I can just hit some of the highlights.

I've been working quite hard to be ready for Saturdays concert and the PBS shoot.  They will be with me most of the day. There are so many of the things that I'd normally do during the day of the concert are being pushed back into the week. Added to that is the scheduling of various and sundry things involved with the show. Plus trying with all my might to have two banjo necks ready to carve on Saturday morning. Plus promotion and booking...As Dan Levenson told me once "I'm just reporting, no complaining!"

Today I went up to Murray Kentucky to do a radio interview for W.K.M.S. 91.3 our local public radio station. I went with the president of Lee Academy Ray Harding. We were there to promote Saturdays concert (do you have your tickets yet?). We certainly had a great time. WKMS is a great station who has a long history of supporting Acoustic/ Folk/ Americana and Bluegrass music. Here I'm sitting with station manager Kate Locte attempting to get my banjo in tune.She' must be laughing at my foolish attempt!

More soon

Edited by - Dan Knowles on 02/19/2013 20:29:35

WillT - Posted - 02/20/2013:  07:18:13

Really coming together on my banjo Dan. It looks even better in person with the wood you've cut.

Dan Knowles - Posted - 02/20/2013:  18:35:52

Will,

I'm glad you like it. I'm planning on carving your neck Saturday during the time that the PBS folks are here. Would you like to be here for the neck carving?

David,

The same invite goes out to you! I know that you are a bit further than Martin, Tennessee! But I can always hope....

Edited by - Dan Knowles on 02/20/2013 18:39:18

Dan Knowles - Posted - 02/20/2013:  19:00:23

Wednesday.... 20th. of February...

Today was mostly a get the shop clean day. My friends Joe and (his son) Eagen Snow came over and we cleaned, hung and moved  pictures around. Cleaning was the biggest job in a wood shop sawdust goes everywhere. Still it is amazing how nice the ole' shop feels with a just bit of spit and polish! 

That said tonight I'll still put up some banjo workin' photos.

This is Wills banjo, I'm profiling the neck and peghead...It's a gimmie the band saw and go! This jig holds the neck in position so I can achieve a consistent angle on the peghead.

The neck comes out of the jig for profiling.

Laying out the tuning machine holes... I'm not sure how this one got out of order... but it did!

David Emery's neck...

Beginning the edge truing...

Laying out neck thickness...

After bandsawing to thickness it is trued on the belt sander...

And on the orbital barrel sander for the inside of the heel...

More soon!

Will1717 - Posted - 02/20/2013:  20:44:47

Dan:

From the looks of the hole in the drywall behind your belt sander it appears that one of those necks went into orbit and ended up in the neighbors shop! (Just pulling your chain!) Did those necks appear at your shop yet? Hope they'll do the job for you.

Bill Rickard 

DEmery - Posted - 02/21/2013:  04:07:10

Dan I appreciate seeing the progress on our slot head. The draw knife and spoke shave is near..............   David E.

Dan Knowles - Posted - 02/21/2013:  05:07:28

Bill,

That hole....

No they haven't arrived yet. But I've got my eye peeled and I'll call you when they arrive.

David,

Looks like Saturday or so....

Dan Knowles - Posted - 02/21/2013:  18:57:26

ALL THE NEWS THAT MIGHT BE NEWS!

Today just after the last photo in this post, I knocked over and broke my trusty  old Kodak Easy Share Camera. I was able to pull these photos out on the SD card, But it is toast (the camera that is). Tomorrow I guess I run over to Wall Mart (the only place in Paris that has cameras) and hunt up a new one. Are there any suggestions? I need it to be able to mount to a tripod, have delayed shutter release, make decent photos (that I can use here) and be reasonably priced (up to $150).

Fortunately I remembered that I needed to add a heel cap for Wills banjo neck ( so it can be carved Sat.). So I got a bit of mahogany and maple  veneer and a chunk of ebony and went to town.

Here I'm putting the glue to it...

Clamped it all down with my not so patented blue foam cawl...

And gave a couple of make up banjo lessons, here with Lloyd. He's getting ready to amaze the world with a cool clawhammer version of the Ballad of Jed Clampet.

Back on Wills banjo I'm truing it up a bit readying it to rout for binding...

Drilling holes for tuning machines...

Here my grandson Chandan is milling necks for the small banjos. It's great to see him do such a good job and do it safely!

"She's gone , gone, gone.

Cryin' won't bring her back!"

see ya soon...

Edited by - Dan Knowles on 02/21/2013 18:59:07

manomusic - Posted - 02/22/2013:  00:56:19

What type of bit are you using to drill the tuning peg holes Dan?

Thanks,

Neil

Dan Knowles - Posted - 02/22/2013:  04:05:35

It's a 3/8" Fournier.

Dan Knowles - Posted - 02/22/2013:  04:06:19

quote:

---

Originally posted by DanKnowles

It's a 3/8" Fourner.

---

Ho C Ying - Posted - 02/22/2013:  04:53:48

You have a good grandson. :)

WillT - Posted - 02/22/2013:  15:17:12

quote:

---

Originally posted by DanKnowles

Will,

I'm glad you like it. I'm planning on carving your neck Saturday during the time that the PBS folks are here. Would you like to be here for the neck carving?

David,

The same invite goes out to you! I know that you are a bit further than Martin, Tennessee! But I can always hope....

---

I will definitely be there!

The Pope - Posted - 02/22/2013:  16:06:44

I have heard of a Forstner bit but never of a Fourner bit. Is that what you meant or am I just ignorant of Fourner? Thanks...

Dan Drabek - Posted - 02/22/2013:  16:42:07

So Lloyd plays clawhammer with a thumbpick? I thought for a minute that you were jamming with Wayne Henderson.

DD

Dan Knowles - Posted - 02/22/2013:  18:02:50

C Ying,

Yes I do have a great  (and not great-grandson) grandson'

Will,

I'll see you tomorrow with bells and whistles!

Pope,

Thanks for the correction. It was too early when I made that post. It is a Forstner.

Dan,

Yes Lloyd plays calwhammer with a thumb pick. Years ago he had an accident with his hand and this allows him to get his thumb in there.

Dan Knowles - Posted - 02/22/2013:  18:16:08

2-22-2013

Today has been taken up getting ready for the PBS folks and tomorrows concert. Sunday I'll make as good of a report as I can of  Saturdays events. Perhaps we can persuade Will, Denton, Bob and some of the other local folks to send in updates as the day progresses. If we had internet at the shop we'd just link up and send it out!

I've been told that we have sold all the tickets so the show will be Standing Room Only! Still if  you are in Paris Saturday evening come by and visit with us!

See you Sunday!!!

dbrooks - Posted - 02/23/2013:  04:14:11

Great news about the concert sell-out, Dan.  Great music deserves a great audience. Everybody will have a  fine time.

David

Tylerb1 - Posted - 02/23/2013:  07:43:43

It will be a great show and lots of fun. Bob

Bufo Bill - Posted - 02/23/2013:  09:51:20

Break a leg mate!

All the best from Bill. :D

Dave1climber - Posted - 02/23/2013:  13:05:31

Dan

It would seem that you have everything in order for Saturday night, I know that it will be a great good time.

Dave

Woodturner - Posted - 02/23/2013:  13:11:45

We got to see a fine demonstration and training opportunity on the art of banjo neck shaping.  It's a pleasure to watch a neck take shape under the wise and capable handle of a master builder.  There were several students on hand to benefit from Dan's expertise. I met several other students for the first time, as well as the future owner of the banjo neck, Mr.Will Turner, which received the special attention this morning.  What a treat to be part of this instruction.

Mr. Chadwick was also in attendance, he's the local high school chorus director and a darn good guy.  Sounded like Mr.Chadwick is strongly considering to join the teaching, learning, and instrument building that goes on every Saturday at Dan's shop.  Mr.Chadwick is looking to build and learn banjo.

Dan Knowles - Posted - 02/24/2013:  10:14:14

Denton,

I'm certainly glad you could be there. We all had a great time!

Dan Knowles - Posted - 02/24/2013:  11:10:26

2-23-2013 Part 1 Early part...

What a day! It was such a large full day (for me at least) that I'm going to post this in two or maybe three parts.Here was the schedule:

7:3o Arrive at shop to prepare for class

8:30 Class begins to arrive and get to work.

10:00 guests for the neck carving begin to arrive.

10:30 PBS Crew arrives

10:45 Shooting  & neck carving comenses.

12:30 Lunch & rest (1-2:30 PBS shoots interviews)

2:30-4:45 Interview with PBS

5:00 sound check

6:00 dinner break

6:45 pre show

7-9:30 performance

10-10:30 pick up and walk home.

That said, lets head on to the day...

First out, here I'm routing David Emery's neck for binding (this is a Friday shot, but I felt it should be here). I'll bind this one on Monday and carve it on Tuesday or such.

After the class got started Kevin (aka. Steve) worked on making some fiddle figure maple bindings. Here they are running them through the thickness sander.

Jerry's working on a banjo...

And Eric is laying out cuts on his guitar neck...

Folks started arriving for the neck carving ceremony... sounds kinder like a wedding don't it! Besides the class we had, Will Turner and his lovely wife Bekka, Denton, Mr Chadwick and the PBS folks...

Here I'm explaining the responsibilities and rights of marriage... oh wait a minute this is a neck carvin' not a wedding. I guess I'm tellin what I'm gettin' ready to do.

Here I'm talking about my almost 200 year old spoke shave...

Denton (woodturner) is getting in for a bit of up close and personal... There the cameraman Terry is aiming in the background..

Now he is shootin' from down low... I teased him about worshipin'... I'm explaining about my cheepo rasp...

I didn't get any photos of the interviews so now it's about 6:45 and we are prepping for the show. David VanHouser, the producer of PBS's show Creative Instincts is conferring the program and shots...

Our opening act was my good friend Martin Paschall. Martin is the pottery instructor at Lee Academy and is a fine musician and singer in his own right.

Next post, the show...

and soon...

Dave1climber - Posted - 02/24/2013:  14:45:25

Dan

That schedule doesn't have any nap time in it, a very full day indeed!  Your shop looks as if you could eat off of the floor, my complements to the cleaning crew, a professional job!  Going by the clock on the wall the film crew didn't waste  any time getting down to business.  I like your JIG for holding the neck for shaping.

Dave

Dan Knowles - Posted - 02/24/2013:  15:04:02

Dave,

They sure didn't waste any time. They were quite well prepared and knew just what they were up to. I try to keep the shop in a clean and neat shape, for when it gets too messy I get a bit crazy and will just start pitching stuff. That is not a good idea in a shop where things cost like they do here. So I do try to keep it up... reasonably... I did get a bit of a nap during the 1-2:30 time slot they interviewed several other folks who are prominent in the local arts scene.

On a side note in this; David Emery called during the neck carving (talk about a man with perfect timing!) and I was able to put him on speaker phone (like I usually do), work and talk with him about his banjo.  That was wonderful timing David!!!

Dan Knowles - Posted - 02/24/2013:  16:24:50

Back to last nights concert. We all had a large time. the house was full the tables were fast.... wait a minute Dan this isn't a gambling movie... In fact the house was full whith very kind excited folks who made performing a joy. We played a wide varieity of material from Old-time County to Minstrel to Classical banjo, to a bunch of my original stuff. These photos were all taken by Michael Varnikee, he did a wonderful job!

Here's the band:

Mark Holladay (guitar, tenor vocals), Danny Conger (fiddle), Me (here playing my Farland Artist Grand), Josh Coffey (mandolin & fiddle) and Sam Knowles (bass, lead, baritone & tenor vocals).

Here I'm gettin' ready to play Amazing Grace on the musical saw. By the way this was the saw I learned to saw with. It was my Great grandfathers, my grandfathers, my dads and now mine.

Playing...

Sam...

Josh,

Danny & Josh,

Danny,

Ole' me,

Sam & me,

With the minstrel...

Mark & Danny,

More soon...

Dan Drabek - Posted - 02/24/2013:  17:47:44

Now, I always thought musical saws were a specialty instrument made for that purpose--flexible and without teeth. But yours looks like a crosscut handsaw. Even has the little notch filed on the back for starting the cut. You must have a lot of sand if you can play music on one of those!  

DSDS

Dan Knowles - Posted - 02/24/2013:  18:26:14

Dan,

That is an old (ca. 1860's) cast steel saw. It is fairly thin, for a hand saw and very musical. It's the one my father played back when we played saw duets. I've go another one that he found me and was the one I played then. Most hand saws can be played, SOME WITH SUCCESS! Ahhh... and some not.

Tylerb1 - Posted - 02/24/2013:  18:51:18

Dan;

The best way to say it s to say the show was just excellent. Good time was had by all. You and the band were just wonderful. Bob

Dan Knowles - Posted - 02/24/2013:  19:37:23

Thanks Bob,

It was great to see you there!

Dan Knowles - Posted - 02/24/2013:  20:04:57

Last of the Concert Photos

Heres Josh wearing out the mando...

Sam...

Mark and I...Danny's back there too.

Mark...

Danny...

Me at the end of the show...

Here we all are after the show... Dan Knowles and his Hot Band.

See ya tomorrow!

Dave1climber - Posted - 02/24/2013:  21:43:31

Sound files?

Dan Knowles - Posted - 02/25/2013:  03:51:49

Maybe soon... I have yet to listen to the recordings.

jbalch - Posted - 02/25/2013:  03:55:43

Sounds like you had a BIG weekend.  Congratulations. 

The photos are great. I'm sure the music and show were magnificent.

Bufo Bill - Posted - 02/25/2013:  04:16:48

Congratulations Dan, wish I could have been there, it looked great fun.

All the best from Bill. :D

DEmery - Posted - 02/25/2013:  04:36:20

Dan those are really nice photos from the concert and I'm glad it was a big night in Paris. Hey thanks for taking the phone call during your busy day Saturday. It was fun to be introduced to the PBS crew and hear about the slot head. Looks like it gets a carved neck this week. I look forward to seeing how it looks. Like all the necks you have carved for me (while this one is different from the other Knowles necks) I know it will be just right. David E.

Dan Knowles - Posted - 02/25/2013:  19:24:49

Thanks John, Bill & David

I do hope to glue on the binding tomorrow and carve on Wednesday. David I wish I had Skype down at the shop. I'd set it up so you could watch. Perhaps I can figure a way to video the carving session by Wednesday.

Dan Knowles - Posted - 02/25/2013:  19:43:05

MORE PHOTOS OF THE NECK CARVING WORKSHOP...

Thanks goes out to Will Turner ( the proud owner-to-be of the neck carved in the workshop on Saturday) who shot these great photos and sent them to me. Here are just a few.

Roughing the neck on the bandsaw...

Carving with the antique spoke shave...

Kevin doing some carving for the camera!

Jerry goes after it with a rasp...

Gouging the heel to shape...

Scratchin' away with a horse hoof rasp...

More gouging...

More shaping...

And explaining...

More tomorrow...