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  1. #16
    Join Date
    Feb 2015
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    Strathalbyn South Australia
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    1,141

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    Quote Originally Posted by scuzyboy View Post
    Hi with the melamine box over the sander I would keep an eye for stress if it’s a typical cast housing I had one from jet that cracked at the motor end nearly impossible to find anyone to repair it. Cheers Peter
    Yes, I see your point! Probably more of an issue will be the weight of the 150mm flex hose hanging off the end of it. I may have to revisit this and get it sorted before I do any damage to the whole thing. I had to add shims to the table at the open end of the drum after I put the melamine box on it, I didn’t consider the added weight with the hose attached either. I have some work to do, thanks again for the tip!

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  3. #17
    Join Date
    Jul 2013
    Location
    Lower Blue Mountains
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    132

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    Quote Originally Posted by Cal View Post
    Yes, I see your point! Probably more of an issue will be the weight of the 150mm flex hose hanging off the end of it. I may have to revisit this and get it sorted before I do any damage to the whole thing. I had to add shims to the table at the open end of the drum after I put the melamine box on it, I didn’t consider the added weight with the hose attached either. I have some work to do, thanks again for the tip!
    No worries just like to save you the pain and expense I went through to get it sorted out. They are quite fragile being open ended, I have seen a mod adding a slotted bar with thumb Screws but is a pain in the When using it.

  4. #18
    Join Date
    Feb 2015
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    Strathalbyn South Australia
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    Well the 5 string is done!

    I got back to it today, cut the nut then drilled and reamed the pin holes. I had to make a temporary saddle (which took a heap of time) and sat it in place. Just so happens it was the right spot! Intonation pretty close to perfect. Cut the saddle slot and drilled the hole for the pickup. Shaped and fitted the saddle and strung it up.












    It goes back to the owner tomorrow.

    I ordered and collected a few new bands for the bandsaw, a 6mm, 12mm and Lenox Woodmaster bi-metal for resawing.



    So I got into making some fretboard stock, Laced Sheoak, Wenge, Blackbean and Laced Woody Pear. There is also some Redgum and Tasmanian Myrtle that I found.





    Getting everything sorted for a bit of production work now. Next weekend I will start on the new moulds.

  5. #19
    Join Date
    Feb 2015
    Location
    Strathalbyn South Australia
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    1,141

    Default A new set of ukuleles

    Started on the new bucks and moulds, all cut out on the bandsaw and a template for each size has been fine tuned. Currently using the router with a bearing bit to finish each piece to the shape of the templates. There are Soprano, concert, Tenor and Baritone.
    I should be able to bend a pair of sides over the bucks at once, hence the thickness of each buck. The baritone will be one side at a time.





  6. #20
    Join Date
    Feb 2015
    Location
    Strathalbyn South Australia
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    1,141

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    Bucks and moulds are now trimmed up, oh how much faster this would have been with a CNC, but once I got in the grove it only took a couple of hours to trim them all up with the router and bearing bit. The bucks will be used in a Fox style bender that I have to hop to and make now, it will give me the repeatability that I am looking for to be able to make a few in a session.
    I will be making duplicates of the moulds also for glue ups.










  7. #21
    Join Date
    Feb 2015
    Location
    Strathalbyn South Australia
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    Almost finished building a “Fox Bender” for the bucks.
    This should make things a little easier to get repeatable results.
    I have som MDF gluing up at the moment to turn a wheel for the screw.






  8. #22
    Join Date
    Feb 2007
    Location
    blue mountains
    Posts
    4,882

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    Wow, Getting seriously tooled up.
    Regards
    John

  9. #23
    Join Date
    Feb 2015
    Location
    Strathalbyn South Australia
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    Thanks John, yes who knows if it will all end up in the dump!

    Handle finished, I was going to use MDF but this made more sense, an off cut from a ukulele neck!


  10. #24
    Join Date
    Feb 2015
    Location
    Strathalbyn South Australia
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    1,141

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    Just trying to get all the timber sorted before I start bending, found some Silky Oak that I millled a while ago. I have a fair amount that can be used as backs and sides.





    I laminated four necks this weekend also, images to follow.

  11. #25
    Join Date
    Feb 2015
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    Strathalbyn South Australia
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    Neck blanks are ready to mark out and rough cut. 9 pieces of timber in each.




    And a little bit of kerfing cut to size, this takes a long time to make and is mind numbing repetitive!


  12. #26
    Join Date
    Apr 2015
    Location
    Warragul Vic
    Posts
    1,093

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    Progressing well Cal. Thanks for taking us on this journey with you.

    Euge

  13. #27
    Join Date
    Feb 2018
    Location
    Shepparton
    Posts
    508

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    I'm with you on cutting kerfing time consuming and not always successful in my attempts, by the look of yours there is a gap on cuts that may be the answer next time I cut kerfing I cut my cuts on a bandsaw which I have to say was less than successful.

  14. #28
    Join Date
    Feb 2015
    Location
    Strathalbyn South Australia
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    I cut mine on the bandsaw also! This is what I have made to get the spacing right.



    It’s not much but I get it to work.
    I have seen an automated system that is great but I can’t afford it at this point.

  15. #29
    Join Date
    Feb 2018
    Location
    Shepparton
    Posts
    508

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    thanks Cal will give this setup a try next time I have to cut kerfs simple but effective looking kit.What is the cut width using the bandsaw?

  16. #30
    Join Date
    Feb 2015
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    Strathalbyn South Australia
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    Kerf ends up at 0.9mm which is plenty to get around the waist of the instrument to a tenor size. I have to check what it is going to be like on a concert and soprano, I suspect that I will have to make another jig with narrower spacing between each kerf.

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