Showing posts with label Design. Show all posts
Showing posts with label Design. Show all posts

Thursday, June 7, 2018

There's Nothing New Under the Sun!

Over the years, I've given a lot of thought to developing a signature look for my guitars and, for the most part, I'm satisfied with that aspect of their construction. Having said that, I'm sure there will be further evolution, as well as minor variations from one instrument to the next.


It's probably inevitable that with the limited canvas afforded by the guitar I'll often find instances of others' instrument designs having arrived at a similar destination in an aesthetic sense; my initial reaction when I discover that the headstock, heel cap, bridge shape or rosette design I invested so much time on exists elsewhere is one of mild disappointment. However, rather than seeking to change my own designs and embark on an endless exercise in tail chasing, I'm learning to accept that there's nothing new under the sun, and that there's no point in pursuing that particular mirage - no good can come from it, and constant disappointment can be the only predictable outcome!


As much as I admire design elements such as, for example, Kevin Ryan's "acoustic flutes", Michael Greenfield's ever-so-cool bridge shape, or Sheldon Schwarz's multiple oval soundholes, they strike me as truly unique designs that help identify those builders' instruments - part of their "brand", if you like. Although they're very inspiring, out of admiration and respect I would never seek to imitate those examples. Instead, I'll continue to be receptive to new ideas that drift into my consciousness, rejecting any that tend towards deliberate mimicry - assuming that I know they do!


With that in mind, I have some exciting "new" design features brewing that will unfortunately only see the light of day once I've built my workshop. I can't wait to turn them into reality!

Cheers
Pete

Monday, September 5, 2016

Irish Bouzouki - Nearing Completion

As this is my first attempt at constructing an Irish bouzouki, the adventure has been a prolonged one - even more so than is usual.

Before I began the instrument, I thought long and hard about the preliminary design. It seems there are few established standards where even the most fundamental elements of the Irish bouzouki are concerned, to the extent that there's even debate online as to what constitutes a bouzouki in the first place. Throw the terms "octave mandolin", "mandocello" and "cittern" into the mix with "Irish bouzouki", and you'll find there's plenty of scope for healthy debate and disagreement!

After I'd drawn and redrawn the body outline any number of times, settled on a headstock shape that seemed to be in keeping with my guitar headstocks, decided on the number of frets to the body and the scale length, construction of a half-body template, then a full-body template, were necessary first steps even before I could consider fabricating the all-important outer body mold.  

Given its narrow width, I was a little dubious about the strength of the first neck I made, and the second version, pictured hereabouts, incorporates two carbon fibre bars extending up into the headstock to provide additional strength and stability. In conjunction with the carbon fibre, a double-action truss rod has been installed in the usual manner.

After I'd fabricated the first ebony bridge and marked the position of the bridge pin holes, I was uneasy about their proximity to the rear edge of the bridge. That bridge was discarded, and I redrew the bridge outline and started again, taking into account what I'd learned from the first attempt.

The instrument body was sprayed and buffed out, using yet another waterbased product that promised so much but fell short of the mark in my estimation. Despite having invested a lot of time and effort, I judged it to be unsuitable, due mainly to its softness and the likely difficulty of future touch-ups. The finish was sanded off, a new finish material chosen, and it was back to the spray gun to begin the entire finishing process all over again.


Even now, with the instrument very nearly completed, I have plans to revisit the body outline I'll use on future instruments. I guess this is a natural process with any "prototype", so I'll think of this bouzouki as a first iteration and the basis for further experimentation and refinement in the months and years ahead.

Fortunately, I enjoy problem solving and learning new skills; this instrument has certainly provided many opportunities in that regard. I'll post photos of the completed bouzouki in the next week or two.


Cheers
Pete

Wednesday, January 13, 2016

Irish Bouzouki - Fun With Moulds

Making jigs and moulds is a messy and time-consuming affair. There are definitely more enjoyable ways to spend one's time, so I figure it's worthwhile investing a little extra effort and expense to get it right the first time.

Half-body and full-body templates
Half-body and full-body templates, with headstock template

While I wait for suitable weather and a break in my IT work long enough to afford me the opportunity to spray finish coats on the four guitars I've been constructing (seemingly forever!), I'm taking the first steps in building an Irish bouzouki - a first for me. After deliberating for some time where design and dimensions are concerned, fabrication of an outside body mould and templates for the bridge and headstock have been my focus in spare moments over the past couple of weeks.

Where construction of the body mould was concerned, my first task was to decide on the overall dimensions in the absence of any universal standards. In the guitar world, the iconic factory models manufactured by Martin and Gibson for many decades have at least served as a loose benchmark for the independent builder. However, as the Irish bouzouki was appropriated to a large extent from the Greek instrument and randomly modified to suit the requirements of a motley band of Irish folk musicians, its evolution appears to have been driven less by tradition than by the whims of the builders and musicians who have adopted it. It seems there are any number of combinations of scale length, body shape and body dimensions in common use, and I finally decided that in the absence of any agreed formula I'd develop something largely on what appeals to my aesthetic tastes. I was influenced a little too by the length of the truss rods I have on hand, my available fretting templates, and my concerns that an extreme scale length and a body join at the 17th fret - as is common practice - would result in a cumbersome, neck-heavy instrument. For better or worse, I've decided on a more conservative 632mm (24.9") scale length, a body width of ~350mm (14"), and a neck to body join at the 15th fret.

Using a set of French curves and a flexible ruler, I tidied up the half-body outline I'd drawn freehand on paper so that the curves transitioned and flowed smoothly. I traced the final outline onto a piece of baking paper, then transferred the outline to a piece of 6mm (1/4") MDF using transfer paper sourced from an art supplies shop.

I jig-sawed the MDF just inside the body outline I'd transferred from the tracing paper, then carefully removed the rest of the waste up to the line using a spindle sander. This yielded me a half-body template that would guarantee symmetry when used as a routing master. To fabricate the full-body master template, I aligned the centreline of the half-body template to a line I'd ruled on a second piece of 6mm MDF, traced the body outline and jig-sawed within the line, then clamped the two pieces together and routed to the line with a flush-cut router bit riding along the inner edge of the half-body template. Flipping the half-body template over and again carefully aligning the centrelines, I routed the other half in a similar fashion. The half-body and full-body templates are shown above.

I know from experience what a dusty mess MDF makes when machined, and of its tendency to deform and deteriorate over time, and made the decision to spend a little more money and fabricate the outside body mould from ply. To do so, I traced inside my full-body template onto a piece of 18mm ply, then jig-sawed inside the line leaving a small margin. Once again, having carefully aligned and clamped the full-body template in place, a flush-cut router bit removed the remaining waste.

I've struggled in the past to accurately align the individual layers when fabricating new moulds, and the solution - now that it's dawned on me - seems embarrassingly obvious. On the second layer of ply, I once again jig-sawed inside the pencilled body outline transferred from the full-body master template, then aligned and glued the two layers of ply together. It was then a matter of routing the waste to the line on the second layer of ply using the first layer itself as the bearing surface for the flush-cut router bit. The process was repeated for the third and fourth layers, with the final mould therefore comprised of four perfectly aligned layers of ply yielding a total thickness of 72mm.



Useful links:
Graham McDonald's, "The Bouzouki Book"
Nigel Forster Guitars - Irish bouzouki page


Cheers
Pete

Friday, April 4, 2014

A Workshop Update

With IT work in short supply, I've been "forced" to dedicate much more time to guitar building over the past couple of months. Well, I'm not really complaining!

It stands to reason, of course, that spending more time in the workshop will increase my output. Nevertheless, I've been pleasantly surprised by my rate of progress as my current guitar projects take shape. With the luxury of two days a week dedicated to building - and thinking about building - I've been able to make significant inroads into these three guitars, as well as identify a couple of steps in the build process that I feel could benefit from further thought and refinement. As usual, the next guitar will be better!

European Spruce/East Indian Rosewood
The guitar pictured above features a European Spruce soundboard, and a very attractive set of East Indian Rosewood back and sides. The florentine cutaway is only the second one I've attempted, and although it represents more work and an increased degree of difficulty, I'm satisfied with the way it's turning out.

Port Orford Cedar/Claro Walnut
The Port Orford Cedar/Claro Walnut guitar featured in recent posts is waiting in the queue, with the body ready for binding and work on the neck largely complete. I'm quite pleased with a new design flourish I've implemented on the heel cap. The "scoop" evident on the heel itself is another new development; the goal being to echo the aesthetics of the headstock and fretboard end in an attempt to tie these elements together from a design perspective. The photographs show these details, with final shaping and sanding yet to be completed, and with the heel cap unattached.

Redwood/Claro Walnut OM
This Redwood/Claro Walnut OM has been languishing in the cupboard for several months while I wait for the motivation necessary to apply the sprayed finish coats. As the other two guitars rapidly approach a similar state of completion, it's unavoidable that finishing, sanding and buffing will occupy the bulk of my time very soon. Having said that, I plan on applying an oil finish to at least one of these necks, a side-effect of which will be that the finishing process will be slightly less time-consuming than it would be otherwise. 

With storage space at a premium, I'll be strongly resisting the urge to begin another guitar until this batch is complete and - hopefully - distributed to new owners!


Cheers
Pete

Wednesday, January 29, 2014

The Modified OM

With the messy job of constructing a new bending form and outside mold finally out of the way, I've been able to make some progress on this guitar over the past week.

The walnut sides bent willingly, as they always do, and I was pleased to see that they conformed closely to the new mold, with the exception of some minor spring-back on one of the lower bouts. The spring-back was a useful reminder that it's advisable to subject the sides of any wood species to a couple of heating and cooling cycles before removing them from the bending form. I have to try hard to resist my innate impatience, and on this occasion I was a little premature in taking the second side out of the side bender, hopeful that such a compliant wood wouldn't require a second cycle. A quick touch-up on the electric bending iron soon had the side sitting obediently in the mold.


With the head block, tail block and kerfed linings glued to the sides, I'm better able to assess the new body shape. Needless to say, I'm greatly relieved that it matches my expectations, and that the time-consuming and incredibly dusty task of making yet another bending form and outside mold has been averted.


Noting the recent emergence of guitars referred to as "modified dreadnoughts", and lacking a more imaginative idea, it seems reasonable to dub my new guitar model the "modified OM"! 

Cheers
Pete

Tuesday, December 3, 2013

New Design, New Guitar

While the task of spraying my Walnut/Redwood OM remains on the "to do" list, I've managed to sneak in a little progress on a new guitar, this time combining a Port Orford Cedar soundboard with the sister set of Claro Walnut back and sides.


I fell in love with the venerable Martin OM when I first saw one many years ago, and as much as I still admire its timeless design and elegant curves, I feel ready to leave it behind me and develop a more contemporary body profile I can call my own.

I build guitars with the fingerstyle guitarist in mind and, taking note of player preferences commonly espoused by players in that style, I've nipped in the waist slightly, reduced the width of the upper bout and rounded the shoulders, the end result of which - I hope - is a comfortable and aesthetically pleasing body shape. The price I pay is the additional work involved in constructing molds and bending forms to accommodate this new design, so it's sobering to reflect on the fact that until the first body is assembled, I won't know for sure that the dimensions will appear balanced and attractive. Building molds isn't exactly my idea of fun, so I certainly hope I don't have to repeat the exercise! 

Cheers
Pete

Sunday, August 25, 2013

A Broken Promise, and Some New Rosettes

After promising myself I wouldn't begin my next guitar until the two I'm currently waiting to spray were complete, I've relented a little and have spent some time fabricating and inlaying some new rosettes over the past week. With wet weather still the norm, and a trip to Africa looming large, it was becoming increasingly unlikely that I'd get to apply finish to those guitars any time soon, hence the broken promise - an opportunity to spend time in the workshop!

European Spruce, with Zebrano, Ebony and coloured veneer rosette
Port Orford Cedar, with Zebrano rostete
Sitka Spruce, with Zebrano and Ebony rosette
Engelmann Spruce, with East Indian Rosewood rosette

I wouldn't tempt fate by proclaiming that I've in any way mastered this aspect of guitar construction, but I'm pleased to be able to produce rosettes like these to an acceptable standard fairly consistently these days.

Cheers
Pete

What's In a Name?

The back and sides of this guitar are of narra, which is an alternative name for a wood that's most often marketed here in Australia as ...