CUSTOM BANJO
Mash's
"Ishfahan"
2017

I have an old Persian carpet which my grand father brought back from Iran before the WW ll .

I got an idea to recreate its pattern on a banjo .


This is the part that I put on resonator back.
I made some modification on birds


The drawing for resonator sides.


Best quality curly maple resonator from Gill .
These lines were carved with carving knives.


It will be stained and painted like the original carpet.





The bird on the fingerboard.

The head is white MOP, wings are of gold MOP and bronze shell , pink abalone chest, gold MOP leg, white tails.








Gold MOP Iris .  black pupil and eye lines are black cyanoacrylate.

Gold beak  grafted.






Inlaid. Vines are black MOP. Some flowers and buds are bronze shell.





Feathers and Scales drawn.

 



Engraving lines are drawn with pencil.
Unfortunately, there is a crack in the largest piece. But it will be hidden by engraving  . . . I hope.



The main flower of the peg head has a crack( layer separation ).  You can see black ink penetrates at the left lower part.
 I decided to replace.




 The older piece was cut out with scroll saw


Feather and leg scales engraved



Then, beheaded for fret slots .   . . .  poor bird!




I carelessly dropped the neck after the overlay was glued and it hit a steel vise on the floor.
The column cracked and caused rattle when tapped.
Again, I had to replace a piece.
Now the column is wider .

FLANGE


The outer part of Gibson style brass flange was cut with jigsaw.

 

The inner part will be made into a new flange.




Brass plate, 2.5mm thick, is prepared on lathe.




Fitted together and welded with Muggy weld “ Super Alloy 1 “.
 At first I tried silver weld, but it needed higher welding temperature and it was difficult to heat up a large object like banjo flange, properly.
 Eventually I failed and I returned to Super Alloy 1, which melts at much lower temperature.
Still it was difficult job for me.



Tulip flower  pattern, which is popular in Islamic art.



Drilled...


... and cut out with jigsaw. The narrow blade can fit in the small cut-out.



Fitted to a Cooperman hide glue rim.

Heel carving


Transcribed with pencil.









Carved with carving knives. This is soft maple and it doesn’t mean carving is easy, but due to the fibers, it needs sharper knives.
The edges are sanded a bit.




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