Bob_C - Posted - 03/21/2012:  15:43:52

I've officially started banjo #2. My first effort came out flawed but functional so with a little experience under my belt we'll see if I can improve. I'm building an 11" openback with a mahogany neck, chechen rim and cocobolo trim. I'm using Rickard hardware and a Dobson tone ring.

Part of my dissatisfaction with my first banjo was my wonky jigs giving me wonky results. I've spent a lot more time on these jigs and I have to say so far so good.

                                                       cheers,  Bob

stigandr5 - Posted - 03/21/2012:  16:33:19

Looks good so far. What's chechen like to work with?

Bob_C - Posted - 03/21/2012:  16:39:02

The chechen I ordered from Cook Woods online. I haven't actually started the rim yet but I think it's a type of rosewood. It seems fairly hard and not too oily. I'll probably get the neck mostly done before I move on.

                                            Bob

DEmery - Posted - 03/21/2012:  17:46:46

Look forward to seeing the banjo. I had Dan Knowles build me a banjo a couple of years ago with a two ply cocobolo rim. Pretty wood and nice tone. It will make nice trim in your project. David E,

Goshen By Dan Knowles

Goshen by Dan Knowles

Bob_C - Posted - 03/21/2012:  18:00:13

Thanks for posting your banjo David, Dan does beautiful work! One of the great things about online forums is getting to see others work (very inspirational).

                                                cheers,   Bob

aeroweenie - Posted - 03/21/2012:  18:32:20

Looks like you're off to a good start.  Keep us posted!

DEmery - Posted - 03/22/2012:  06:36:03

Thanks Bob. I have enjoyed Dan's creative style and musical nature of his banjos. I will watch your progress with your project. If you want please add me to your friends list so your feeds will hit my page. David E.

Bob_C - Posted - 03/27/2012:  14:55:36

Well, more progress on the neck, I have the fret board glued on. The heel cap and both head plates also. Rough shaping the neck was so much easier with a Stew Mac dragon rasp.

(Sorry about the fuzzy photos...)                                       cheers,   Bob

charleybill - Posted - 03/27/2012:  14:59:50

Love it! I'm going to have to get some cocobolo!

DEmery - Posted - 03/27/2012:  16:15:36

Bob the photos are fine and your progress really nice. Keep posting your photos as things come together. David E.

Bob_C - Posted - 03/27/2012:  17:47:40

Question, It seems that if you scoop the fret board and then level the scoop with the relief scoop in the tension hoop you will end up with different action (bridge height?) than if you level the unscooped fret board with the tension hoop, yes....?

                                                             thanks,   Bob

Bob_C - Posted - 04/15/2012:  08:57:02

Ok, making progress with mistakes along the way. Here's the dowel stick underway.

Bob_C - Posted - 04/15/2012:  09:31:01

Work on the rim using methods I learned from Randy C. and Dan Pennington.

d13design - Posted - 04/15/2012:  09:32:38

Hi Bob - progress is looking good. I'm just embarking on my first build and already looking forward to my next - fixing all of the things I'm sure to do wrong with this one. That wood looks beautiful too!

rudy - Posted - 04/15/2012:  12:31:46

Looks great!  Careful with sanding Coco and Chechen, both are reported to trigger strong alergic reactions.  It appears that folks become more sensitized to certain woods by multiple exposures to sanding dust.

stanger - Posted - 04/15/2012:  13:26:26

quote:

---

Originally posted by rudy

Looks great!  Careful with sanding Coco and Chechen, both are reported to trigger strong alergic reactions.  It appears that folks become more sensitized to certain woods by multiple exposures to sanding dust.

---

Yup. Always use a good mask with fresh partlcle filters.

Stuart Mossman, the maker of Mossman guitars, developed a severe sensitivity to rosewood. It grew so bad he had to sell the company, and it eventually led to his early death from chronic pneumonia due to the allergic reactions.

regards,

stanger

Bob_C - Posted - 04/15/2012:  13:39:02

Thanks for the encouragement. I've been pretty good about covering up and wearing a mask. So far, so good.                    cheers,   Bob

Waltj - Posted - 04/15/2012:  14:28:58

It is looking great!.  I learn a lot  from you guys.  Thanks for sharing.

Walt

XXXris - Posted - 04/15/2012:  16:04:31

This looks great; thanks for posting!

rubicon - Posted - 04/15/2012:  19:53:58

The rim is beautiful great job on the neck !!

aeroweenie - Posted - 04/15/2012:  19:54:26

Absolutely gorgeous rim!  Nice job on the dowel stick, gives me some guidance for the next one I make.

Bob_C - Posted - 04/15/2012:  20:08:22

Yeah, I couldn't think of a good jig to cut the dowel stick angles on my band or table saw. I have a nice block plane and it took me less than 45 minutes (maybe 1/2 an hour...) to taper it that way. The 3/4" tenon cutter I found on ebay.

                                                                              Bob

Bob_C - Posted - 04/16/2012:  20:01:28

I've had requests for jig details so this is what I've got. The neck shaping jig is about as simple as can be. It's a 2x4 about 21" long with three 2" holes drilled for clamping the neck blank and a couple of smaller holes for clamping to the bench.

Bob

Bob_C - Posted - 04/16/2012:  20:05:59

For drilling the bracket hardware I just drilling an appropriate size hole in a piece of MDF at the desired height. Then figure out my hardware spacing, mark it with tape, clamp a backer to the rim to minimize tear out and drill away.

                                      cheers,  Bob

Booger McGee - Posted - 04/16/2012:  21:02:37

Thanks for the pictures of the jigs!  I am slapping myself in the forehead now that I see your bracket -drilling jig.  It's genius compared to the way I did it (measured out and marked each hole)!

Booger

Bob_C - Posted - 05/07/2012:  22:20:29

Here's the jig I made to support the neck while fretting. The dead blow hammer is from Harbor Freight and works well for fretting. I'll have finished banjo pictures tomorrow.

                                                   cheers, Bob

Waltj - Posted - 05/08/2012:  02:52:37

Very nice work, Thanks

Walt

Bob_C - Posted - 05/08/2012:  09:35:35

For the finish I filled the grain by sanding with 220 wet/dry paper dipped in egg white. You work up a slurry of egg and wood dust and work it into the pores, let dry, sand it smooth and repeat until the pores are filled. Usually 2 or 3 times depending on the wood you're filling. The actual finish was 7 or 8 coats of Tru Oil. When dry I rubbed it out with rottenstone and walnut oil.

Bob_C - Posted - 05/08/2012:  09:45:45

And here it is (mistakes and all...). Gotoh tuners that I aged with Birchwood Casey Perma Blue, Rickard hardware and Rickard Dobson tone ring. Goat skin head from Mid East music (thanks for the flesh hoop Verne (mbanza)). I misplaced a couple of the position markers and I need to make a new nut (strings are too close to the edge of the board).

                                                                    cheers,  Bob

aeroweenie - Posted - 05/08/2012:  19:59:18

I think you've done a great job on this banjo!  What is the depth of the rim plus tone ring?

Bob_C - Posted - 05/08/2012:  21:10:40

Thanks! I originally was thinking of doing a fairly shallow rim but as I built things evolved and I ended up at 3". It definitely sounds a lot better than my first banjo (my wife even noticed the improvement in tone...).

                                                                            Bob

Jonnycake White - Posted - 05/09/2012:  17:19:58

Very nice job and thanks for sharing all the in-progress pictures.

rubicon - Posted - 05/09/2012:  21:08:08

Nice job on the banjo !!!

BNJOMAKR - Posted - 05/10/2012:  03:01:02

Good job and nice detail work!

d13design - Posted - 05/12/2012:  00:03:13

That's beautiful - the selection of the wood, finish colour, metal work and head compliment each other really well. Very jealous 

Bob_C - Posted - 05/12/2012:  09:00:40

Thanks everyone. Inspiration for the aesthetics came from the usual suspects (Colin Vance, the Romero's...). Since my budget is more in line with an entry level instrument I had to go with building my own to get what I want. Lots of little flaws but I can live with it.

                                                     cheers,  Bob