A few rubber bands are used to retain the strings against the fretboard and to prevent them from slipping
off the loop posts of the tailpiece. This greatly simplifies the process of removing the neck for test
fitting, etc.
Go to page 1...Rim construction, glue-up and forming basic rim.
Go to Page 2...preliminary mounting of the head.
Go to Page 3...Making the neck.
Go to Page 4...Making the neck, continued.
Go to Page 5...Installing frets.
Go to Page 6...Bringing it all together.
This is Page 7...Outer rim band and miscellaneous details.
Go to Page 8...Finishing and final assembly.
Go to Page 9...Basic banjo drawings and notes.
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Click on images below for larger views.
A few rubber bands are used to retain the strings against the fretboard and to prevent them from slipping
off the loop posts of the tailpiece. This greatly simplifies the process of removing the neck for test
fitting, etc.
The outer rim band is composed of three layers totaling 1/4" in thickness by 1-1/4" wide. This method of
constructing the rim band was chosen to eliminate the need of heat bending the laminations. Each individual
layer is thin enough to conform easily to the form after a 10 minute hot water soak in the tub. Cut them
all 36" long innitially. This instrument was done using two walnut laminations with a maple
lamination sandwiched between for contrast.
Shown is an easy way of uniformly thickness sanding them with a small stationary belt sander after first
cutting them on the bandsaw. Round off the bottom edges of the 90 degree belt fence that comes with the
belt sander and adjust the gap between the bottom of the guide and the sanding belt for the desired finish
thickness of each lamination. They are then pushed under the fence against the direction of belt travel
until they can be held firmly enough from the rear to safely pull them through. Remove a small amount
of material at each pass...multiple passes may have to be made.
Shown is the form used as a glue-up jig for the three laminations which make up the outer rim band.
Glue two 16"X16" pieces of 3/4" particle board together and draw circles at 7", 11", 11-1/4", and
14" diameters. Bandsaw straight across to the inner portion and remove the waste piece. Cut out
the outer ring and trim into segments..these are used as clamping cauls. Sand the outer face of
the form, spread glue on the faces of the cut going to the center, and wrap it tight with a few
layers of masking tape. Wrap the surfaces of the outer sections with masking tape to prevent
them from being glued to the outer rim band.
A gluing form is cut from two layers of 3/4" particle board glued together. Make it large enough to allow
clamping cauls to be formed when cutting out the main 11" o.d. portion. Finish the outer diameter to
11" and cut the inner diameter to about 8". The sections removed when cutting out the form can be re-cut
to form the clamping cauls which hold the 3 laminations in place while being glued. Cover the gluing
surfaces with masking tape to prevent the finished piece from sticking. Remove the laminations from
the 10 minute soak and lightly dry them. Cover the appropriate surfaces with glue and clamp one end down.
Continue around the form, clamping as often as possible. When the end is reached, trim off the excess
and clamp down. Let dry overnight, remove from form, and sand edges smooth.
Outer rim band as it is removed from the glue-up form.
Next step is to sand the edges down with the belt sander or other means as you have available.
Outer rim band as it appears after installation. Trim the ends at an angle to match the neck heel and
round over the ends with a 3/4" radius. Center the rim hoop on the rim and notch the bottom slightly
in the area of the end bracket. This is done to allow the rim band to be positioned flush with the
top surface.
Position the outer rim band at the correct location and drill the two mounting holes closest to the tailpiece and centered between the tabs. Drill 3/4" down from the top edge with a 3/16" brad point bit. Cut a small piece of thin wood and glue it lightly to the outer rim band above the end bracket location. This will carry the force of the tailpiece when string tension is placed against it and prevent the outer rim band from deforming. Attach the outer rim band at these two points and proceed in order to the other four bolt locations.
Insert a #10 flat washer between the outer rim band and the rim at each point of attachment to allow the head to be tensioned without being restrained by the rim band.
The tailpiece bracket mounting...the outer rim band acts as a spacer to position the no-knot tailpiece
to be in alignment with the end bracket.
A 1/4" flat washer (3/4" O.D.) was added under the end bracket to align the tailpiece and end bracket correctly.
Bend the no-knot tailpiece to align correctly with the end bracket if you choose not to add the outer rim band. (You wouldn't choose to do that, would you?)
Banjo after outer rim band is installed. It's now ready to completely disassemble, sand, and finish.
After removing all hardware from the rim, drill a shallow 3/16" hole where the dowel retainer screw bears
against the rim.
Add a #10 copper rivet with the shank cut short in this hole when re-assembling to take the pressure of the
retainer bolt.