Bluegrass Banjo

Online Lessons

Other Great Sites

First step in making a resonator is to create the veneer that will become the back of the resonator. In the pic below there are two pieces of veneer poplar that have been glued together with the grain of the first one turned 90 degrees from the veneer sheet that is on top. Now more glue is applied so we can place the third sheet of the final veneer on top also turning the grain 90 degrees from the one underneath of it. On this resonator the top piece will be walnut. 

This is a pic of all 3 pieces of veneer with glue spread evenly between all three pieces.

Next all 3 pieces are put into mold that gives the back of the resonator its special concave shape. then the mold is put into a hydraulics press and put under 10,000 LBS of pressure and let to dry for 4 or more hours depending on the humidity of the room. 

Once the glue has dried the the back is taken to a ban saw and cut to a round shape about 1/2 inch in diameter larger that the resonator wall rim.

 

After the 3 ply walls are glued and dried then the back is glued on. You will notice the back hangs over by 1/4 inch or less.

 

The we take it over to the band saw and trim it as close as possible.

 

 

After the walls and back of the resonator have been glued together then it is put on a lathe and cut down to it correct size and the groves for the binding are cut into the sides and back.

 

After staining the resonator the stain has to be removed from the binding.

This processes of removing the stain from all the binding takes about 6 hours.