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Concert Ukulele (The Acacia model neck is pi$$ed!)

This is where we don't want anything but evidence of your finest wood butchering in all its glorious, and photograph laden glory. Bring your finished products or WIP's, we love them all, so long as there's pictures, and plenty of 'em!

Re: Concert Ukulele

Postby Malc2098 » 24 Feb 2021, 16:56

One neck carved and rough sanded.

I started by carving the neck profile at both ends.

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I then found my spokeshave that can't have seen the light of day for a good 20 years!! :oops:

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Then some P80 Abranet and some elbow grease.

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Then more elbow grease!

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I just love this pattern maker's' vice!
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Re: Concert Ukulele

Postby novocaine » 24 Feb 2021, 22:01

Delightful job Malcom. Definately one of the most nerve racking jobs.
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Re: Concert Ukulele

Postby Malc2098 » 24 Feb 2021, 22:14

novocaine wrote:Delightful job Malcom. Definately one of the most nerve racking jobs.



Thanks, Dave.

I must confess, there are times when I struggle to think in 3D. So, for this task, I maintained the drawn middle line, because the shape is symmetrical. I drew on the side and rear faces the outlines and tried to keep within those as I rasped. I used a flat microfile and the round and flat sides of a rasp to make the shapes and surprisingly found it quite therapeutic so long as I didn't try to bite too much off in one go.

I also tried to keep the workpiece in the vice in the symmetrical position, which required at times rasping left handed. But even then, I found that not too difficult if I took my time. If I put the workpiece in the vice with the heel facing left or right to enable a bit more purchase or control of the the shaping, I had to turn it over and do the same to the other side, or I could take too much off one side. I would frequently return it to its symmetrical position in the vice and eye the curves for symmetry.

Not too shabby, I thought, for my first try.
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Re: Concert Ukulele

Postby novocaine » 24 Feb 2021, 22:23

I carve in facets. Ill find you a link to how i do it. It really works. Basically mark a line to carve to on both sides. File and sjave away to the line on both sides. Mark the next line and carve to that.
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Re: Concert Ukulele

Postby Malc2098 » 27 Feb 2021, 17:49

Both necks carved and sanded to 80 grit for now.

Machine heads dry fitted. Family branding dry fitted.

Time to make the fretboards.

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Re: Concert Ukulele

Postby DaveL » 27 Feb 2021, 21:47

So two questions.
Are the truss rods adjustable?
The top neck, Gareth machine heads geared or just straight through?
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Re: Concert Ukulele

Postby Malc2098 » 27 Feb 2021, 22:12

Thanks, Dave,

So, two answers.

1) No, and probably not necessary.

2) Straight through 1:1

https://maderasbarber.com/tonewood/en/ukelele-concert-headmachine/4105-ukelele-tuner-ping-well-rm-1789n.html
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Re: Concert Ukulele

Postby NickM » 27 Feb 2021, 22:23

These look amazing.
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Re: Concert Ukulele

Postby Malc2098 » 28 Feb 2021, 13:23

NickM wrote:These look amazing.



Thanks, NM.

But there's still a fretboard each to go, and then the bodies! Loads more can go wrong yet! :D
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Re: Concert Ukulele

Postby Malc2098 » 28 Feb 2021, 19:10

Fretboard banks cut using the jigs cut by Dave Neale of Lasercutz.

One is rosewood, the other is figured maple, and somewhat pink for maple.

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Re: Concert Ukulele

Postby DaveL » 28 Feb 2021, 19:55

Not jealous of that jig at all

Looking good, wii they be radiused or used flat?
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Re: Concert Ukulele

Postby Malc2098 » 28 Feb 2021, 20:57

DaveL wrote:Not jealous of that jig at all

Looking good, wii they be radiused or used flat?



Thanks. For the ukuleles, they will be flat.

I can show you where to buy a CNC download of the plans. And I can point you to a member who can make the jig from the plans.

You'd also need to know the scale length for the template.

It's all quite simple and not expensive.
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Re: Concert Ukulele

Postby AJB Temple » 28 Feb 2021, 21:10

What does the jig do apart from keep the saw upright? Will it cope with a radiussed fret board?
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Re: Concert Ukulele

Postby novocaine » 28 Feb 2021, 21:13

Fret board is in the post. 24.7" scale thanks.

Looking good Malcolm.
Fun bit now.
Fret pressing. Im expecting a a sexy little press rather than the more prosaic copper hammer.

Jig sets the fret position as well as holding the saw vertical and setting the depth.
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Re: Concert Ukulele

Postby Malc2098 » 28 Feb 2021, 21:42

AJB Temple wrote:What does the jig do apart from keep the saw upright? Will it cope with a radiussed fret board?


The jig registers the blank at each fret position directly under the saw blade. Each scale length requires a separate holed template.

For my purposes, I have a 15"/351mm template for concert ukuleles and a 25.5" for guitars.

The jig maintains the saw vertically and at right angles to the blank.

The jig sets the depth that the blade cuts into the blank.

The jig can cope with a curved blank, although the bottom of the cut will be flat, and therefore deeper in the middle than at the edges.

The blank can be cut flat and then radiused, or radiused first and then cut. It's up to the luthier.
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Re: Concert Ukulele

Postby Malc2098 » 28 Feb 2021, 21:44

novocaine wrote:Fret board is in the post. 24.7" scale thanks.

Looking good Malcolm.
Fun bit now.
Fret pressing. Im expecting a a sexy little press rather than the more prosaic copper hammer.

Jig sets the fret position as well as holding the saw vertical and setting the depth.




Nothing quite so sexy. I will use a caul pressed down by my pillar drill, preceded of course by a soft mallet.

I will also wick CA glue into the slot before pressing the fret in.
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Re: Concert Ukulele

Postby DaveL » 28 Feb 2021, 21:49

Malc2098 wrote:
DaveL wrote:Not jealous of that jig at all

Looking good, wii they be radiused or used flat?



Thanks. For the ukuleles, they will be flat.

I can show you where to buy a CNC download of the plans. And I can point you to a member who can make the jig from the plans.

You'd also need to know the scale length for the template.

It's all quite simple and not expensive.
So does the jig need to laser cut, or could I cut it on my Workbee CNC?
I know I could cut fret slots with the CNC, but it's needs very small end mills which means very slow cutting and I already have the correct saw for cutting the slots.
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Re: Concert Ukulele

Postby Malc2098 » 28 Feb 2021, 22:09

DaveL wrote:So does the jig need to laser cut, or could I cut it on my Workbee CNC?
I know I could cut fret slots with the CNC, but it's needs very small end mills which means very slow cutting and I already have the correct saw for cutting the slots.



No. The plans I got were intended for 5mm acrylic, but I suppose they could be adapted for other sheet material. Dave Neale also laser cuts thin timber and mdf. It just suited me not to have to design and make the jig and templates from scratch.

It's the templates that need to be accurate and benefit from CNC manufacture, and the registration pin hole on the jig needs to be spot on.

Having set the jig up, which was pain to get right, it only took about 10 minutes per blank and I have the satisfaction of knowing they are all in the right position and square. (unlike the first ones I did 20 years ago where I drew a pencil line with a square and cut loose! :o )
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Re: Concert Ukulele

Postby novocaine » 28 Feb 2021, 22:46

Oi ya cheeky sod, some of us still do it freehand. :lol:

I reckon a the pillar drill is the fanciest of presses going. ;)
Not sure on the merit of glue in the fret slot. If you cut them right and used a decent fret the tang should be enough to hold it. Worked for years on old fenders (note the gibson used glued freta in the 80s and look how that worked out........ same as the non glued ones lol)
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Re: Concert Ukulele

Postby Malc2098 » 28 Feb 2021, 23:01

novocaine wrote:Oi ya cheeky sod, some of us still do it freehand. :lol:

I reckon a the pillar drill is the fanciest of presses going. ;)
Not sure on the merit of glue in the fret slot. If you cut them right and used a decent fret the tang should be enough to hold it. Worked for years on old fenders (note the gibson used glued freta in the 80s and look how that worked out........ same as the non glued ones lol)



Got me sussed! :D But, I bet your freehand is way more accurate than my freehand, which is why I wanted a jig and template.

I'm not sure about the glue, either, but I'm using cheap materials, e.g. the thin fretwire for the frets. I've bought the cheapest gents saw that I could and so its kerf is not related in any way to the wire. So it's a bit of belt and braces. Much coming out of America recommends the glue either before or after pressing the frets, presumably to take up any gaps.
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Re: Concert Ukulele

Postby DaveL » 01 Mar 2021, 01:04

Malc2098 wrote:
DaveL wrote:So does the jig need to laser cut, or could I cut it on my Workbee CNC?
I know I could cut fret slots with the CNC, but it's needs very small end mills which means very slow cutting and I already have the correct saw for cutting the slots.



No. The plans I got were intended for 5mm acrylic, but I suppose they could be adapted for other sheet material. Dave Neale also laser cuts thin timber and mdf. It just suited me not to have to design and make the jig and templates from scratch.

It's the templates that need to be accurate and benefit from CNC manufacture, and the registration pin hole on the jig needs to be spot on.

Having set the jig up, which was pain to get right, it only took about 10 minutes per blank and I have the satisfaction of knowing they are all in the right position and square. (unlike the first ones I did 20 years ago where I drew a pencil line with a square and cut loose! :o )
So where can the plans be bought from?
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Re: Concert Ukulele

Postby Malc2098 » 01 Mar 2021, 12:36

DaveL wrote:So where can the plans be bought from?



I bought them through Etsy.

https://www.etsy.com/uk/listing/624694127/fret-slotting-jig-digital-plans?ref=hp_rv-1

They come with the ruler templates for a number of scale lengths including 34, 35 and 36 inch bass scales, I think.

I didn't use the supplied rulers, because I had already had the ruler/templates made with a centre line along the ruler and a 6mm hole at the nut and each fret position along the centre line. I had them made for the scale length supplied with my instrument plans.

I was going to design and build one out of wood and ply, but then I found this one, and as I was already commissioning Lasercutz for other stuff, I had him make the jig and added a hole for the centre registration pin, and four holes for four pins in the corners to keep the template/ruler on track as it progresses through the jig.

I think it's the accuracy of the template/ruler and how it registers with the jig. I don't see any reason why the supplied rulers and pointer won't be any less accurate than my way.
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Re: Concert Ukulele

Postby DaveL » 01 Mar 2021, 12:56

I had just found the jig plan on etsy, I have cut perspex on the Workbee, so I think I will buy a set.
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Re: Concert Ukulele

Postby Malc2098 » 01 Mar 2021, 13:09

DaveL wrote:I had just found the jig plan on etsy, I have cut perspex on the Workbee, so I think I will buy a set.


Great. Hope it goes well.

As posted on my Fret Slot Jig WIP, Dave Neale found that some of his acrylic thickness varies and so when we came to put the jig's joints together, some were a bit loose where the sheet thickness was thinner, and he had to make another from a different sheet which fitted much better.

Edit: I can't see any reason why this can't be made in something like 6mm MDF so long as the joints' gaps are amended accordingly.
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Re: Concert Ukulele

Postby DaveL » 01 Mar 2021, 14:47

I think I will buy some perspex sheet, I think it will be stronger in use.
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