DIY Network

Old-Time Banjo, Part 6: Internal Resonator From "Handmade Music" episode DHMM-208

	Banjo-maker Dave Ball plays a handmade banjo.
	Dave explains to host Jeff Wilson the purposes of the banjo's tone ring.

This episode of DIY's Handmade Music focuses on the second phase of building an old-time banjo. With the tone-ring now fashioned and attached to the rim, this segment covers the creation of the internal resonator.

Materials and tools used in this project:

Maple stock
Padauk stock
Ebony stock
Kerfed lining
Table saw
Band saw
Lathe
Drum sander
Drill press
Hand-held router
Pantograph router
Hand saw
Epoxy glue
Woodworker's glue
Clamps
Clothespins
Sandpaper and sanding blocks

Safety Alert: Always wear safety goggles or safety glasses when
working with wood, power-tools, saws, drills, routers, etc.

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The old-time banjo, unlike its bluegrass counterpart, features an open back and tone ring.

Old-Time Banjo: Internal Resonator

Part of the distinctive sound of the banjo comes from the addition of an internal resonator on the back of the rim. Not all banjos have them, but for luthier Dave Ball, they are standard issue. A resonator may be a reflective, circular structure made from wood and installed on the back of a banjo to augment the tone by projecting the sound of the strings being plucked outward toward the listeners. It was first designed in the days before there was electrical amplification. The old-time banjo being built in this project, however, uses an internal resonator.

According to Dave, the purpose of this design is more to "resonate" than "reflect" -- thereby creating a bigger sound. It consists of a thin internal maple cylinder, and leaves the banjo with an open back. The outer and inner rims are bridged with a black material that, at first glance, might be mistaken for ebony. In fact, it is hard, modern material made by impregnating paper with epoxy-resin producing a hard, durable surface that is actually used to make circuit boards. Dave prefers this material for its resonating quality, but also because he likes the look of a black finish for the backing.

To create the ring, Dave first employs a circle-cutting jig to a rout the material into shape (figure A). He then adjusts the jig to cut away an inner circle, and he's left with a ring that spans the two rims (figure B). He prefers using this synthetic material because he can order it in the desired thickness and its density reflects sound perfectly. It's also tough. Over the lifetime of the banjo Dave will never worry about this resonator's durability.

Figure A

Figure B

The inside rim, like the outer rim, is supplied to Dave by a rim-making specialist. The thin inner rim does have one drawback in that it lacks ample gluing surface. That's where the kerfed lining comes in. A 1/8-inch thick lining is glued onto the inner rim and clamped into position with clothespins as the glue dries (figure C). Once the lining is dry and securely attached to the inner rim Dave sands level the surface with a sanding board. A portion of the lining will be routed out later in order to accommodate binding.

With the kerfed lining attached to the rim and sanded, Dave is ready to assemble the resonator. Normal wood glue will suffice to hold it in place (figure D).

Figure C

Figure D

	Figure E
	Figure F

Dave carefully places the rim onto the reflective face (figure E) and lets the glue dry for at least a day.

Once the glue dries, and as part of the banjo-making tradition, it is at this stage that Dave signs his "work of art" along the inner rim (figure F).

In the segment that follows, fits the neck to the rim with the aid of a specially cut dowel stick.

RESOURCES :

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To order this book from Amazon.com, click here.

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To order this book from Amazon.com, click here.

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Jubilee Community Arts is a regional, community cultural center dedicated to preserving and presenting the traditional arts of the Southern Appalachians. The organization's stated mission is "to promote, preserve and present the performing arts of the Southern region and to nurture the cultural milieu responsible for the birth and evolution of these and related art forms." The organization owns and operates the Laurel Theater, a 19th century converted church located in the Fort Sanders community of Knoxville. The building now houses an acoustically and visually excellent concert hall and archives of concert and field recordings.
Web site: www.jubileearts.org

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To order this book from Amazon.com, click here.

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To order this book from Amazon.com, click here.