Ser#11-9996
Got this banjo from a good buddy of mine, and it was in really sad shape.
The banjo had been in a fire, and the rim, and neck both had fire damage on them.
The neck has no fingerboard left, and only part of a peghead overlay, also snapped off at the heel.
The rim was burnt on both sides, and a little of the lip that the tube rests on was crumbly.
I stripped it to bare maple, and you could smell the charred wood.
Forgot to snap a pic when it was stripped, so I will start, with rim repairs done, and stain, with lacquer re-applied.
Tone ring was hell to get off, but I managed, after about two hours of carefully tapping it free.
Rim refinish
After repairs, stain, and 6 coats of clear
As you can see, it is nearly the standard Gibson prewar rim, which is what it actually is, Gibson made these.
It is turned for the Trujo specs.
Area where the most flames got to it, was darker, which is sort
of visible here, but on a Trujo, most all of the rim is covered with the
tone ring and tube
Tone ring after removal, and buffing/polishing
Rim reassemble
I sent the hooksets for replating, so I am using 4 long hooks, to
hold the head on, so I could check the new tube, and tension hoop, until
they return
Hooks came back, and now I got a set of 2 pc flanges on it, standard
"Tube and plate" now, and it can accept a standard resonator.
I will use an import "Masterclone" one I have handy.
Next to the standard sized flathead rim assy.
About 5.5" deep, total
Neck Work
I chose to take the fire ravaged old plectrum neck, and not only save it, but turn it into a 5 string neck instead.
I feel like I can set this thing up, to be a Thor's Hammer of a 5 string, and there just are no Trujo 5 strings, with the exception of a few custom made ones.
And with the addition of a full depth resonator and flange, we can only speculate to as "tone"
This is mainly to hone skills, that are not part of my usual tasks, and I do this in between other projects, that are on the bench.
Sometimes I need a break, to think, and this helps me to not dwell on a certain job.
Kinda like whittling on the porch a bit.
The pyralin, as you can see, was melting away.
I will leave it on for support, while I reglue the peghead ears.
It got so hot, most of the hide glue has let loose.
The piece on the upper corner, is the one that was between the two
carved wood "fans", on the front
They are charred, but still usable
Cleaned backside
There is alot of wood missing from the sides, so I will have to
build it up with veneers
The 5 string ramp, will be laminated 1/4" basswood square dowels
I will repeg the heel, and seal off this old repair, that is holding
just fine as it is.
Ready to glue the ears
Clamped 8 hrs
Rear pyralin removed,and sanded smooth
Still some charring showing....
.....As is on this end
...and this side
I cut a fingerboard, off of a 30's RB 3 neck profile, and left it
wide, so I could work it down as I wished
I added a Maple/ PurpleHeart/ Maple veneer stack, under the board,
and clamped it, since I do not want to mess with binding.
I will put in pearl marker dots on the side of the fingerboard.
Clamped 8 hrs
Roughed in, and Marked for inlays
I will use these on the board
after glueing and shaping the first section of the ramp.
Second second added, as was heel cap, and roughed to profile
Some small strips on the face of the neck, where wood was burnt
off.
There will be veneer up this side of the neck as well, to gain the
original profile back.
Checking heel fit on resonator.
very good
Temp heel cap, made from scrap,. to check fit
Contoured face of heel, to original profile
Sanding down the side, up top
Laying in pieces of basswood, with glue and wood chip filler.
There is alot more wood, and a lot less glue, than appears here,
it is wedged tightly into the crevice.
Roughing in some more, bringing board edge down to profile
A little more profiling on the ramp
Now to veneer this side
Enough lip was left, to make this work, so I glue it on, and pull
it over, with tape.
After drying, ready to cut down
This is all that's left, but now it is back even again
Still need a little more veneer at the bottom face. after sanding
in.
Adding new 4 layer heel cap
Adding new 4 layer back strap
After rough in
With front veneers added
All smoothed up
Peghead was made very thick, for a reason.
I want a big meaty peghead, to go with this big meaty banjo, and
also, I want my tuners to be fully recessed into the peghead, like a Weymann.
Starting to enlarge the tuner holes
I have a very strange mind, and it will show, in the finish of this
neck.
remember, it was a victim of a fire.
There will be wood exposed, where the wood is still nice, and a
design over bad spots, with the new ramp showing its laminates.
Adding a small bit of filler, to smooth the grafted heel area.
Most of this, will be sanded off
Changing the base color of the Embellishments
My inlay jig
I have a setup, where the string goes arond twice,
pinning the neck into my jig, while allowing the blocks to be inlaid, to
remain exposed.
I learned this from "Gulliver's Travels"
It binds the neck in nicely, but gives me the abilty
to move it slightly, if I encounter high and low spots
My router base, that runs on tiop of the 1/4" bar stock "lands".
It is very smooth, and manageable.
By far, the best jig I have had for this type of operation
Very good visibilty, and I have a fan to blow dust away from the
hole
Painting my blocks to be inlaid, with Tempura.
It is EZ to scribe, and washes off
Scribed #1
A little fuzzy on the periphery, but Rosewood does that, and I need
to put on a new bit, this one is older.
#2 ready to slide in
#2 fit in, # 3 cut
All in, filled and glued, ready to level
Ready to fret
Finish starting to cover
Side dots, which are real MOP have been added added
Installing Fretwire
All fretted, leveled and crowned
I am drilling the tuner holes, for a "Full" recess, on an offset
Grover reproduction geared peg.
Embellishments have been .....embellished a little more, and more
to come.
I am thinking on what MOP will go on the peghead, probaly not those
lightning bolts tho.
I will use a "T" for Trujo" and an "X" for Experimental.
Or...Mde in TX. :)
A mock up look, on how it is coming along
Onward!
Quick jig for routing peghead overlay, and reverse
Adjustable legs, and plastic slides
Screwed to the table, and supported on the other end
After routing and inlaying
Checking tuner fit
Drilled 5th peg, and added 5th string nut
Now for the front inlays
Extension allows me to rout the cavities easier
Added in the nut
After finish is completed, I now have the pegs in, fully recessed,
and amber buttons.
The "Flame" around the inaly, goes with the theme of this burned
up ressurected plectrum neck, that is now a 5 string.
The flame looks really nice, not like this pic.
Finished out resonator, exception of the inside, which I can do
later if I want to.
I dyed the bindings vintage amber, as they were pure white, and
I like the aged look.
You can see the back, in the final pics.
FINAL PICS
You can see here, where I left the fire scarred peghead sides, a
vintage amber, to match the scheme of amber pegs, and bindings.
The red on the side of the neck, and the dyed amber veneer, all
are related, to the fire the original neck was in.
Here you can see the flame job, and corrsponding colors on the buttons,
and veneers.
I stained in some colors, and lines, to enhance the charred wood,
and effects.
I have the neck directly attached, with action preset.
I can add a lower Co Rod if I wish, with no modifications, but there
is really no need to.
I am at a 5/8" bridge, and that is a fairly low action, so I will
jump it up, to a fancy compensated 19/32, as this is just the setup bridge.
Sound is very crisp and clear, not tubby at all, much brighter than
I had anticipated, so I think it has a really good potential, from here.
I took it to let some Pro players have at it, and they are were
very impressed with it, and said it can hold its own, no problem.
It now is equipped with a custom 19/32 bridge, by Jim Farquhar, Rome Ga.
Its going to my pal Barry!!!!!!!!!
and it is only fitting, Barry has nearly every homemade instrument
I have ever made, and I hope they pan out for him someday, but so far,
i haven't gotten famous!
He makes me these little name tags, for my custom stuff, and I fitted
his, over the soundhole jack, so that can remain open, if he wants to use
it.
It is stamped with my "V", I have been using that same
stamp since 1976, on my motorcycle cases.
I also stamped the rim, right at the heel
The red color you see, under the logo plate , is the serial number
of the rim and the paper is a short explanation of what it is and what
was done since it is so oddball .
It's best to have some starting history.!
And my card, like in a Stromberg Guitar :):)
And off to Barry it went today, I will see it in AZ real soon!