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May 24, 2020 - 11:36:11 AM
1245 posts since 4/13/2017

Is there anyone out there who can take a 3D model of a 1 piece flange and CNC it out of brass? I modeled a 1 piece flange to the dimensions of Golden Gate/Saga flanges, and instead of the standard holes, I made it as similar as I could to Rob McCoury's banjo, the one his father in law made, in appearance. I realize Rob's is a tube and plate design but still one piece, but it is so much easier for me to build a banjo with a standard 1 piece flange.

May 24, 2020 - 3:08:39 PM

205 posts since 5/13/2009

Hawthorn banjos had brass top-tension parts in the past. Don't know about now.


May 25, 2020 - 3:06:29 AM
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288 posts since 3/19/2003

What you may want to do is look for a company that performs water jet cutting in your area. You supply the CAD or some can design from a photo(s). Custom car and motorcycle makers use these companies for one-off designs.

Another consideration is 3D printed sand mold casting which after design and printing it is then shipped to a foundry. There you can have a metal formula made, poured, and finished by yourself or possibly the foundry.

Out of the two, the water jet would be the cheapest.  3D sand casting would involve shipping a VERY heavy casting which would add up the cost quickly.

May 25, 2020 - 3:22:08 AM



21707 posts since 7/6/2005

Harry Lane milled his flanges from solid brass billet. Some were very thick and he started reducing the bulk in later years.

May 25, 2020 - 4:55:17 PM
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1547 posts since 10/11/2004

Steve Ryan makes them & last time I talked to him he was going to make more. He did round holes in a couple of mine instead of the Gibby style.

May 25, 2020 - 7:41:27 PM

10828 posts since 6/2/2008

Contact Chris Sorenson at CompanionBanjo. He posted within the past few months about new flanges from his company and the possibility that he could offer custom hole shapes.

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