"Gluing the front and back to the thin sides will give a weak joint. If the corners are removed to put purfling on, the top will pop right off. So a lining is glued onto the sides where the top and back go. The lining is cut almost all the way…"
"My band saw technique is a bit rough and the back of the neck isn't flat. A spindle sander will take the high points down quickly. Check the neck with a straight edge, mark high points, sand away. Repeat. Repeat."
"I'll use a chisel to take off a lot of extra wood. The grain on this mahogany is fairly predictable; if it kept changing direction, it would be hard to control the chisel. I'll switch to a surform file in a bit. Those don't care which…"
"I'm going to make a neck out of mahogany. I could either glue a number of smaller pieces together to make a neck (very economical but involves a lot of tricky scarf joints) or cutting the neck out of one large piece of wood. I'll use the…"
"I'm using a surform half-round file to thin down the heel section of the neck. MAN, I love the way it goes through mahogany like cheese. The half-round makes getting the curves in easier.
The heel will be attached to the ukulele body, so it has…"
"To give the heel a nice symmetrical shape, I made a plexiglass template (I put masking tape on it just so it would show up in the photo). Line the straight edge up with the centerline, draw profile. Flip template and repeat.
I might take a bit more…"
"The neck is mahogany and I'm using maple ears for a nice contrast. I doubt it will show up in this photo, but there's thin pieces of walnut between the two. It is about the same color as the mahogany now, but will look different when the…"
"The head stock is usually wider than the neck, so extra pieces called "ears" are glued on. I used a spring clamp to hold the head stock to a clamping board piece of Formica (you don't want the glue sticking the head stock to the…"
Alan you've created some great instruments! And some great photos. We'd love to see a Builders Blog on making the new acoustic. I'll add it to the Builder's Progress Blogs group. And a tour of your shop blog as well.
Thought I saw you marching with the Ross clan in the parade, but never was able to locate you after it ended. I was around doing various things, pretty much all over the place, until 4:00, and I kept my eyes open. Oh well. It would've been great to meet in person. Perhaps another time. Until then, I'd be thrilled to get your recommendation on the book on flutes. Slainte!