KARL'S
"FAVILLA BRO's"

WORK PAGE

12-13



INITIAL PICS
 


Interesting design with some reflections of Lange and Iucci involved.


 

Tension bolts have a head akin to the head of a blind rivet. one is missing
 


 
 

Heavy fret wear, well loved and played
 
 
 


One celluloid button, and a replacement tuner bushing, I'll try and make that nicer
 
 


A lot of problems on bottom edge of resonator, missing much of the marquetry
 

That is what should be there.
We will measure it and see what we can obtain today, that will blend.
I'm certain that it will be a total change , there is too much gone.
 
 


I see something of Super Paramount in this view
The tension nuts are the same as some Iucci's
 


 


 

Nice engraving, I like the "Punchmarks"



REPAIRS


Adding in a new section of binding


After heat press, working  the frets
There is a large knot in the neck right in the area of a bow
I cannot be sure how long the neck will stay down if at all, under tension
We will see later


Stripping


Blackening inlay


Sealing all marquetry before sanding.
It is taking very much cyano to fill all under the voids


All sealed and taking clear on neck, rim and back of resonator


I have all the old broken marquetry from the side


Inlay dyed and neck taking on clear


Here is the knot in the neck, the warp is right in this area.
I will press it once more but it is still very soft here


Rim ready to assemble


Will protect the old gold with the Nikolas


Old skin is torn, we will go with Renaissance



ASSEMBLY


Now to make the one missing tension bolt


I will use a pneumatic nail gun nail
The head is made offset as the original


My threader does not like working on hardened steel but is cutting well enough to make the thing work


Painted gold and installed


Trying to install neck, oiling the board at the same time.
With the plastic head pulled properly, barely clearing the neck joint....


Poor pic, but it shows that the stretcher band on head is already against neck joint and can not go further down
This is because it is 2 times as wide as original flesh ring.
Neck must have some trimmed off in this area, will wait for permission.



REVERSAL 12-13
Excessive neck bow under normal tension-Truss bar required

After I set the instrument up and allowed it to set a few days it had severe Warp, or Forward pull.
Being as it is a multilaminated neck both under the fingerboard horizontally and vertically it just has lost all of its tension as glue joint after glue joint failed over time.
The new fingerboard inlay was created by Dave Nichols, Custom Pearl Inlay on a board I had slotted and sent up to him.
 


As usual Dave never fails to please, that's a hard set to replicate.
 


I will trim down the sides to binding width while I wait on a carbon rod for truss installation



Board removal


I thought I would pull the frets for a look and WOW, am I glad I did!
BAR WIRE!
Like on old Martin Guitars
No regular fret wire could have ever been used in these slots and had I refretted in the beginning we would have had to either use Martin Bar Wire or.........replace the board!
Fortuitous!
 


Look at the slot width
Bar wire was used to help in trussing Martin Guitars but just like on this instrument when they lose retention, up cometh the neck.
 


These laminates are dried all the way out and have no retention either, I can move them around with my knife
 


Chiseling off the board.
Its basically just coming up in pieces with no real pressure on the chisel
See how it separates from the laminate....
 


This shows how low a retention the fingerboard/laminate assembly has become over time.
 


 

Now for the bottom laminates


Again, not very stuck, no hammer needed
Going carefully so as not to gouge into the base wood
 


Taking my time ,  my chisels are super sharp
When it is all cleaned off, I will run thin cyano into the center laminates to revitalize the adhesion of the side to side aspect.


 Cutting the laminates for under the board

Cut to profile
 
 
 


Ready to press with hide glue


Wax paper barrier helps


Now for the board, I'll bind it first


Ready to glue, Ill place 3 drift posts to make sure the board stays centered in clamp off


It will stay in 4 days in these temps


A little finish applied, that's all for now
Next I will cut the end off and fret the neck  and add side markers and relieve the area on the heel to make clearance for the medium crown head
 


 


I'll cut that on out now and touch up the edge


All fretted and runoff trimmed down
 

I can see some of the dye in the laminate bled over into the maple laminates
Unfortunate, but I cannot remedy.



SETUP


I changed one inferior screw and washer on the D tuner and I replaced the one ivoroid button with a spare MOP I had in the drawer


Final polish and wax

The one extra nut that was in the case fits this thread so I used it to back up the big thumbwheel, looks right

Good fit now and room to adjust, neck angle came back as I'd hoped

Setup on GHS compliments of www.bedfordbanjoshop.com
5 /8 Grover bridge now that the neck has some angle
The old marquetry is in the zip lock bag, we still have not heard back from Karin Rost after 3 months of trying as to if or if not they will make us this marquetry.
Not real happy with their customer service, am looking else where when I have time.
 
 


 
 
 
 

There must have been armrest posts of some kind in the threaded holes here on top
 

Banjo is playing nicely up and down the range of the board, with a nice full tone,.
One never knows how an off make banjo will sound but this is as good  or better than any Lange Archtop, more akin to the Iucci in tone projection
These 2 extra brackets were in the case, I can find no place for them and they are too big for armrest holes
 


Resonator Binding
Created by
E.L. Henson
Falling Waters, West Virginia
http://www.elhensoninlayanddesign.com/

After many months of searching when I could find time, A banjo friend did some searching...
Thanks to Jay Downing, for finding Lee for me!


Lee sent me some .500 marquetry from his on-hand stock that has enough elements to suit this particular design.
To have the original style made up proved impossible for any reasonable costs.



Even though the resonator has a few small warps and this cavity is not a perfect .500", it is going to work just fine.


Since it is vertical grain, it can look different shades from different angles


One quick wisp of walnut to brown it a tad, it is a little reddish with just the clear
The White/Black breaker lines are taped off


Looks darker here......




Less dark here.......its simply light refraction and vertical grain opposing horizontal.

Now to finalize this with clear coats.


Final Pics










Ok, at long last, she is ready for a trip across the pond.
I hope Karl finds it playable to his liking, it has been a long journey for me!
Thanks for watching
Vinnie