Project Ukulele

[zenguitar]

Thanks guys

It was seriously stressful waiting, and a great relief when it came out so well. I really had doubts about one of the splits closing fully.

Going forward, now I've had a chance to examine the back I've discovered that I won't need as many cleats as I feared. The braces will do a lot of the work. And I've decided to put a flatter curve on the new braces just to ease the stress on the repaired back.

Just off now to make a start on those braces.

Andy

[Frisonic]

So Andy, if it is you that's won that £160m how much do you think it would change your life? For example, my guess is that rather than pay someone to finish building these ukes you would instead build yourself a workshop fit for a god, sure... but would you still have time to moderate these forums or dump us in favour of a higher form of philanthropy? Or just go mad for a few years on fine wine and dubious women!

[zenguitar]

Ah Frisonic, now there's a thought....

And I still haven't checked my ticket yet... But it's £166 Million, not 160... and just to put that missing £6,000,000.00 in context...

That alone is enough to purchase a fine Mews residence in Central London, a small farm in the country with enough space for a multitude of workshops and studios, an orchard, and some woodlands. Then to equip the workshops and studios, including some CNC machines, get training on Autocad and using the CNC machines, stock up with loads of materials...

And, of course, fine wines, fine whiskies, copious amounts of cider, and a constant supply of the finest, most dubious, women

And yes, I'd still be here and enjoying myself. The only difference is that instead of downloading pdf's to help answer questions about equipment I don't have to hand, I would be resisting the temptation to buy one or two for my own collection so I can test my solutions first

But until that happy day...



Here's a pic of the new braces already radiused and ready for glueing. I've decided to take a few extra precautions to help avoid future problems with the back. So first of all, I've put a slightly flatter radius on these, 2mm on the lower bout and 1.5mm on the other two. I'm also going to cut them lower and generally make them a lot lighter so the whole back can flex a little more once re-assembled. And I've also decided to glue them on one at a time using clamps rather than do them all together with the go bar deck. That will avoid the risk of the go bars rocking the braces over and hitting the back (if you remember, I had a few battles like that originally and have to consider whether that might have contributed to the problem).





And here's that first brace glued. I used the hide glue again seeing as everything was to hand and everything went smoothly. I'll glue the other two over the next two days, and then add cleats where needed.

Andy

[Folderol]

Very pleased to see these pictures. Great stuff

[zenguitar]

And what do you do when you've glued the first brace?

You glue the next one





And as you can see, this time I dug out the Klemsia type clamps because they have a longer reach.

And then, I did some boring but useful stuff. I put the drill in a bench mount, chucked up the brass bristled brush, and cleaned up a bunch of stuff. I do like keeping my tools in good condition

Andy

[zenguitar]

OK, I know it's not exciting, but for the sake of completeness...





2 shots of the third brace glued. All things being well, tomorrow I'll make the cleats and glue them too.

I won't comment on how someone else came to be given MY winning lottery ticket!! However, I am amazed at how otherwise intelligent people agree to be identified as lottery multimillionaires.

Andy

[Wonks]

I hope you aren't thinking of being a professional Uke builder Andy. This would have to be the world's most expensive Uke by a long way you if you wanted to make a profit. Have you set yourself a date to finish?

[Studio Support Gnome]

I dunno Wonks.... an old mate of mine by the name of Gordon Markendale, used to build ukes for George Harrison, and oh boy, can he can take TIIIIIIIIME to produce stuff.....

[Wonks]

Andy has yet to finish. Gordon may yet be outdone!

[. . . Delete This User . . .]

I've got an SG i started rebuilding 12 years ago, still in bits,,... i think the record is safe.....

[Wonks]

And how's Dave B's Frankenstein coming along?

[zenguitar]

I hope you aren't thinking of being a professional Uke builder Andy. This would have to be the world's most expensive Uke by a long way you if you wanted to make a profit. Have you set yourself a date to finish?

Yep.....

EVENTUALLY !!!!

But if I was building professionally I would be doing it very differently. For a start, I would need a proper workshop. And I would be working full time, not a few hours each afternoon. And I would be using a lot more jigs, moulds and machines.

This project is more about what someone could achieve using basic tools and techniques working in their shed.

But once this project is finally finished, I will be building the jigs and moulds for a 'production model' that could be built much quicker. That will include a side bending machine, a sanding thicknesser, router templates for necks, fretboards, braces, fret slotting tools, jigs for cutting binding channels, and so on.

I already have all the woods and hardware for the production prototype, Koa front back and sides, Indian Rosewood neck, very pretty

Andy

[Wonks]

Go for it! But the Uke craze could all be over before you get started. I hear bagpipes could be the next big thing.

[zenguitar]

Bagpipes!! I'll need a lathe for those!! Would you settle for Bagpuss?

But meanwhile, all three new braces are in place.



And from there all I needed was to put some cleats across the glued splits... and here they are



I used offcuts from the back, cut into diamondish shapes and bevelled the top edges. Then applied them with hide glue again. No need for clamps, these were all rubbed joints. You apply glue to the cleat, place cleat on the back, and rub the cleat against the back until it grips. Then hold in place for a few moments until the glue starts to gel. They hold in place easily, the gel stage is enough to hold them safely. Hide glue dries in two stages, the gel stage is the initial grip, and then it fully dries by dehydration. As the water dries out, the glue shrinks and pulls everything together tightly.

Day off tomorrow

Andy

[Jumpeyspyder]

Bagpipes!! I'll need a lathe for those!! Would you settle for Bagpuss?

Sorry couldn't resist

[zenguitar]

Back to work this afternoon...

And time to get those braces in shape. And rather than high and tapered, this time it's low and square.



Lovely pile of wood shavings there



And then it was time to start cleaning up the body ready to refit the back.



Guess I'd better put some thought into how I clamp the back on before I rush ahead

Andy

[Frisonic]

Looking good Andy.

[Wonks]

I want to see it finished by tea-time.

[zenguitar]

Oh, it'll definitely be finished by tea-time, just not sure which tea-time

Meanwhile, back to the back...







And that's the old braces out. Just need to trim them back flush to the kerfings. Then trim out the kerfings to accept the new braces.

With good planning, and a little luck, the new braces were a good match to the old ones. So mostly it was cleaning out the old notches, just one edge needed extra trimming. So now it's ready to glue tomorrow.





And I took some time to prepare the Go Bar Deck of Doom once more, and to make sure the Go Bars are all the same length. I'm doing all I can to minimise risk.



I still haven't decided whether to go with the white glue or the hide glue. I'll sleep on the thought, but a lot depends on the weather tomorrow I think.

Andy

[Folderol]

Ah yes. The case of the exuberant go-bars

You seem to be really zipping along now - great stuff

[Jumpeyspyder]

I still haven't decided whether to go with the white glue or the hide glue.
Andy

What about yellow glue - aliphatic resin adhesive?

[zenguitar]

I still haven't decided whether to go with the white glue or the hide glue.
Andy

What about yellow glue - aliphatic resin adhesive?

Ah... it's times like this when I wish I had all the references or links to hand. But, essentially, 'Aliphatic Resin' is a posh name for PVA. It tends to be applied to the part of the family that has less slip, Titebond and some Humbrol wood glue are good examples, and because they have the yellowish colour those are known as yellow glue. But the white Humbrol glue I'm using is just fine for the purpose.



It all went smoothly, no crises to deal with. Apply glue to kerfings, apply back, place first 6 Go Bars, final adjustment, and then load up the rest of the Go Bars.



I've got to finalise the headstock designs now, and get back to carving the necks.

Andy

[Dan LB]

Looks like a job very well done - let's just hope the go bars all stay in place until the glue dries!!

Dan

[Frisonic]

Can't wait to see what you decide to do for the headstock and what drives your choice (tone, balance, robustness, aesthetics).

[zenguitar]

Headstock design... not too big, not too small, looks good, relatively straight string pull. Gotta do some lay out drawings and finalise a couple of designs. But largely head-scratching, thinking, drinking and smoking, until I have a clear mental picture of what will work. Once I have that, I can draw it accurately and make templates.

Meanwhile...

the back is back





All in one piece and looking good. And one very relieved luthier

Gotta get online and order replacements for the sacrificed bindings soon. And maybe see if there's anything else I might need for the future that I can get it at the same time.

Andy