Product Work LogName Taylor Faulring Date: 121103Product : 5 String Bluegrass BanjoDate/Time: Activity: Banjo Resonator wood filling Comment/Suggestions12-12-02 and Banjo rim/tone ring cleaning :6:32:008:30:19 Commentary: This started out with • Use wood filler having to plug the holes where the a little less118 Minutes original resonator wall lug mounts messy and would have gone with wood filler that plug the hole would later be sanded down to be as easy as you flush with the resonator wall. After can. doing this I started cleaning the banjo’s • Should have aluminum rim/ tone ring by cutting of used a dremel some of the metal burr’s that were left too for the over after the rim holes were drilled. banjo rim’s Along with the burr’s I had to clean off metal burr’s the residue of the cutting tools. I left over. started off with a brillo pad and then later used warm water and soap to keep it clean and ready to build.
Product Work LogName Taylor Faulring Date: 12-23-02Product: 5 String Bluegrass BanjoDate/Time: Activity: Working on Banjo neck and Comment/Suggestions12-23-02 getting it prepared :5:31:49-7:08:19 Commentary: I started this day by taking • Be very careful97 minutes the neck and checking the banjo tuning peg with the holes to see if the geared tuners would fit replacing of the correctly. To my despair they were too 5th string nut as small so I got a drill and a 3/8” drill bit and you may scrape widened the banjo’s tuning peg holes. After the fret board a this I sanded the neck just a little bit to little bit which I start the final shaping so that it would be did. ready to get the wood stain put onto it a • Be careful little later. I then moved on to take the 5th whenever using string nut out which holds the 5th string in a drill bit as you place at the start of the tuning machine to may make a plug the hole and replace it with a bone nut hole larger than which would improve the tone and look of you need, I did the banjo. This started with drilling out the not do this to old plastic nut and then using a razor blade my banjo but it to cut out the rest of the plastic, then I can happen used permanent glue and filler to get the very easily. banjo’s hole plugged. • Needed a 1/8” drill bit for 5th string nut.
Product Work LogName Taylor Faulring Date: 122502Product: 5 String Bluegrass BanjoDate/Time: Activity: Building the Banjo pot and Comment/Suggestions12-25-02 construction :7:19:53-9:00:00 Commentary: The first step to the • Make sure construction of the banjo’s pot is laying there is not99 minutes out all the banjo’s components. The pot enough stress consist of L-brackets, brackets shoes, on any of the brackets nuts, the rim, the tailpiece, the components on banjo head which I used a Remo the pot, for it renaissance low crown head, armrest, could cause tension hoop, flange plates, and the breaking of resonator mounting hardware. I first parts. had to install the rim brackets and then • Check all ran the head on the rim, which is held components down by the tension hoop which has before the notches that the banjo hook and nuts build, I had a run into to tighten the head on the rim. single co- The hooks then run into the flange ordinator rod plate which mounts onto the rim that did not fit brackets and is able to hold the banjo the banjo’s pot together to mount to the resonator. neck bolts. Lastly, you take the T-bracket’s and install the 1st and 2nd one across from each other on the rim, and the 3rd where the tailpiece is aligned.
Product Work LogName Taylor Faulring Date: 120503Product: 5 String Bluegrass BanjoDate/Time: Activity: Neck and Resonator Sanding, Comment/Suggestions120503 then putting the first staining on the :4:00:00- wood.7:00:00 • Plastic binding Commentary: To start this step in the on the banjo’s180 Minutes building of the banjo you take a nut and medium coarse sandpaper and run it resonator on the neck and resonator to get the purfling does imperfections out of the wood and not hold wood make sure it is even all the way around stain real well. the neck, along with this step you must • Follow the follow your sanding methods with the grain of the actual grain of the wood to make sure wood more you are not getting uneven on the closely. wood of the banjo. Once this process is • Use cloth over I had to get the can of wood stain without lint on that was oil based so that the wood them. would absorb the stain very easily and go deep, and you need to mix it up very good and then once the stain is ready to go you grab a lint free cloth and dip it into the stain can and apply it onto the wood again following the grain of the wood. I did this for both the neck and resonator until all the wood was covered with the first coat of stain as even as I could apply. After I applied the stain I let it sit and dry for about two days straight so that the wood would really soak in the stain.
Product Work LogName Taylor Faulring Date: 120703Product: 5 String Bluegrass BanjoDate/Time: Activity: 2nd Staining and Sanding Comment/Suggestions1207003 : Commentary: After waiting for about5:30:29- two days I checked over the wood and • Make sure the8:34:05 stain from the two days previous to wood is make sure that the neck and resonator stained evenly184 minutes had been done correctly the first time. and correctly. At this time I took some very fine • Don’t ever use sandpaper and scraped the wood stain on plastic where it was need so that the neck parts or bone would be ready for the second staining parts on the and all imperfections would be cast banjo. out. As last time I ran the stain over the banjo’s neck and resonator like last time following the grain and not over adding stain to get certain parts splotched up. On the second time around on the resonator only needed stain on the back and sides as the first stain on the inside of the resonator was sufficient enough for the final product. The only thing stained inside the resonator was the top of the walls inside the resonator as the first time I had to skip this.
Product Work LogName Taylor Faulring Date: 121003Product: 5 String Bluegrass BanjoDate/Time: Activity: Connecting the banjo’s pot to Comment/Suggestions121003 the resonator and using the mounting :1:20:02- hardware3:50:04 • Make sure the Commentary: This process was a very two flange150 minutes tricky part on the bringing of the many plates on both components of this banjo together. This sides of the step involved precision measuring and banjo’s pot are alignment to make sure that the even to the rim hardware that held the pot and so that no resonator together was a real pain. alignments are First, I aligned the pot on the resonator off to make and then took a pencil and fit it down sure all things in between the flange’s holes and are even. marked at two spots on the banjo’s • Check the resonator so that the alignment would resonator wall be correct on both sides. Then I before starting measured 3/8” above the bottom of the to drill into it resonator and then I took the drill with so that you will a 1/8” drill bit and started the hole for not warp any the wall mount of the resonator wood. mounting hardware. Once the two holes were drilled and started the rest had to be turned by hand until both mounts were even with the wall of the resonator and then I aligned these with the pot’s t brackets and once I finished all of the measurements the pot fit snugly atop the resonator.
Product Work LogName Taylor Faulring Date: 121103Product: 5 String Bluegrass BanjoDate/Time: Activity: Placing the Geared Tuning Comment/Suggestions121103 Pegs onto the banjo’s peg head :2:15:07-3:18:37 Commentary: This task involved • Make sure the making sure the holes in the peg head right drill bit is63 minutes were ready to let the tuners get on the end of positioned correctly into place. Along the drill so the with getting the four planetary tuners tuners do not attached I had to hammer in the 5th have too much string geared tuner into the wood so leeway. that it would not move from its place once the tensioning of the string is placed on it. Once this task was done I was able to align the tuners up to be ready for stringing the banjo.
Product Work LogName Taylor Faulring Date: 121104Product: 5 String Bluegrass BanjoDate/Time: Activity: Drilling neck bolts for the co- Comment/Suggestions ordinator rods/ Cutting heel of the :121103 neck11:06:53- • A more precise12:38:08 Commentary: This step is for the bolts measure of that hold and connect the neck of the how tall the92 minutes banjo to the rim of the banjo as to make neck’s heel and the neck not bow and keep the neck at the rims a necessary angle for the right height of tension hoop the strings on the neck. To start Me and fit. my facilitator took the lag bolts and slowly wound the screw into the holes at the heel of the neck. Once the first bolt was in we had to align the second bolt to the first as well as check the fit on the resonator of the banjo. Once the bolts were in place I was able to mate the neck and rim of the banjo. It took about 3-4 tries to cut the neck’s heel down with a sharpened file and through trial and error match the two together. Once the neck fit I joined the neck with the single co-ordinator rod to the rim.
Product Work LogName Taylor Faulring Date:Product: 5 String Bluegrass BanjoDate/Time: Activity: Connecting the Neck to the Comment/Suggestions121403 pot construction and final assembly of :10:45:06- the banjo.11:05:18 • Commentary: This started with the rim20 minutes and neck already joined and the neck was set at the right angle. Then once the neck was joined you attach the resonator to the pot and the banjo is complete.
Product Work LogName Taylor Faulring Date:Product: 5 String Bluegrass BanjoDate/Time: Activity: Setting up the Banjo for Comment/Suggestions maximum sound :12160312:22:06- Commentary: This part was most •12:58:78 enjoyable as I was finished with the project part of the banjo, but now it36 Minute was the time to where I could change and mess around with the banjo to get the maximum sound I wanted and liked to hear out of a banjo. I chose the head that had the best resonance, the bridge I had built by myself and shaped myself, and also choose the strings that I wanted put on my banjo. First, I strung the banjo by running the strings from the tailpiece to the tuners. Second, I cranked the head down with the tension hoop and tension hooks until the head was to the tightness I liked. Lastly, I installed the bridge under the stings on the head and tuned up the string and then set the bridge to where it needed to sit for the correct tone. Then I set the tailpiece which was the last thing for this project.