December 02, 2009
Workshop Wednesday |
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A quick scan of The Workshop on a busy Wednesday reveals more than a few projects underway. The guys are as busy as Santa's elves, moving steadily along with our clients' dream guitars. At one end of the shop Todd has just finished buffing a Standard model built from African Limba and finished off with a golden yellow "Korina" lacquer.
Wait a minute! What's up with that? Left-handed Standards always take me back to the very first time I saw this shape. The familiarity of the form is temporarily suspended and It's almost as if I'd never seen one before.
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This particular instrument was ordered with tortoise shell binding, and it's a great combination with the color of the guitar. Todd is now methodically assembling all the hardware, which is gold-plated, before moving on to the wiring bench. Each step of the way our guys are careful to take all the time the job requires and they don't rush anything.
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A few steps away Dave is prepping a neck joint on another custom Standard. Tom has just finished the neck which features a maple fingerboard. Gary put a few light coats of nitro on the fingerboard before the frets were inserted, and now Dave is ready to join the two parts.
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We fit each neck in a precise way that can only be done by hand. The neck socket on the body is undersized, and in this case it's Dave who will open it up to fit the neck perfectly. But wait... there's more!
Here's the dry fit, and look... it's a Kahler trem! Yes folks, we still do 'em just like yester-year. I've still got my favorite Pepto-pink Kahler-quipped Chaparral with a built-in Nady transmitter. That thing rocks!
Well, enough of my yakkin' let's turn it up to eleven and get these people their guitars. The holiday break is almost upon us.
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December 04, 2009
Week-end Wrap-up |
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It has been a very hectic week here in New Hartford and the weather has been crazy too. Yesterday it hit 67 degrees here, which is pretty insane seeing how it is supposed to snow tonight!
Dave is making good progress on the Kahler-equipped Standard—here's the blended neck joint after being roughed out with a spindle sander.
The rest of the blend will be done with sandpaper, taking in excess of an hour to complete. Quite amazing when you compare it with the time it takes to bolt on a neck. You can see the area he's working on from its different color. That's because the guitar was already pore-filled which darkens the wood. The lighter area is where the raw mahogany is exposed.
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About twenty five feet from Dave's bench Todd has a Standard 12-string bass up on the leveling bench. This one has a quilt maple top that has been finished in our transparent black. It's a difficult finish to get exactly right. For the longest time I wasn't happy with the hues that black stains used to achieve their "black." But after lots and lots of experimenting, we've hit upon a solution that looks exactly right.
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Our process avoids the "dirtiness" in the pores that you see on inexpensive jobs. Another nice touch on this instrument is the matching headstock overlay which turned out rather well. The ivoroid binding really sets it off too.
We use a double truss rod arrangement on these 34" basses to counteract the tension of twelve strings and allow twist control as well. Todd is about to hand sand the headstock with a smooth block in order to get the finish dead flat.
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A quick look inside the spray booth finds some "stock" models in progress—a Monaco III, another Standard a pair of Talladegas and a Monaco. There's always something cooking, but everything will have to simmer over the weekend while we chillax. See you next week!
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December 07, 2009
Morning Blend |
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Starbucks' ain't got nothin' on our man Dave. He's up with the roosters and in the shop before the sun comes over the mountain to the east. He's already working on the neck blend that he started on Friday and he's determined to finish it up. He's got it roughed out with the scraper and files to the point that it's all about the hand sanding.
He's got it down to about a 220 grit right now so it's slow going. He just keeps running his well-trained fingertips over the surface to identify any inconsistencies in the shape—then he sands a little more. This ain't his first rodeo folks, so he knows where he's going by braille.
We'll stop back a little later to see how he does.
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| Neck Blend Completed
It's lunchtime here in New Hartford, and it has been a busy morning. Dave has finished the neck blend on the Standard model and with a new coat of pore filler it's up on the rack to dry for two days.
Looks pretty nice doesn't it? This one is getting a bit of an unusual paint job, but that's for another day. Now it's time to finish eating and get back to work.
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December 09, 2009
SuperPro Guitar on the Level
Just a quick post at the end of another busy day. As I passed through the finishing area I caught Todd on the leveling bench with a custom order Monaco SuperPro. If you look closely, you'll see that it's just a little different than stock.
We'll have to turn back the clock on this one and give you a full rundown on the build and the back-story soon.
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December 11, 2009
Chambered Music. An Evolution of Sound |
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Beginning in the late 1980s we've added chambering to our list of sound tweaking tools—and when the Artist model was launched it became mainstream with us. Those early examples of hollowed-out guitars were just solid body instruments with a pocket (or holes) cut into the mahogany back and then covered by the maple top. The Artist added the f-hole, but it wasn't until after we'd made the move to New Hartford that we really started taking the whole chambering thing to a new level. Of course, the Newport and the Improv were logical extensions of our quest, but let's concern ourselves with the semi-solid guitars for this post.
Our first change was to modify the Studio's chamber size and add the undercarve to the top. Most chambered guitars (including the original Artist models) are hollow underneath but only arched on the outside. By getting the dimension of the top over the chamber down to a consistent thickness we were able to gain some amplitude and noticeably shift the resonance of the guitar. This led to more experimentation with shape and size.
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The Talladega is the most obvious recipient of the data that we collected—its horn-shaped form and rounded corners serve to reduce standing waves.
It's exactly the same thing speaker enclosure builders do. Our collaborations with fellow luthiers and aerospace engineers brought us up to speed on several important fronts. An in-house laser vibrometer was at our disposal as well. It's a device that lets you take a "movie" in real time of the vibration patterns on the surface of the instrument. Pretty cool stuff. In the end, the techie tricks only served to attach hard numbers to what we were learning by ear.
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Talladega Pro Chambering
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In the case of the Talladega, we were trying to tailor the sound of the guitar to accentuate the articulation of the notes without becoming too hard or harsh. The Double-D pickup concept was going to have plenty of mids, but we wanted the guitar to be capable of the kind of twang that country and roots rock players could dig. Also, the Tally is capable of combining the two pickups in series for a big humbucking sound, but we didn't want the bottom to wash out either. The
Talladega Pro is somewhat different in that it supplies a warmer, darker tone for players who are jumping to humbuckers from bolt-on Strat-type guitars. I think that in both cases, we've succeeded.
Another instrument that has benefitted from our attention to chambering is the Standard. We'd made some hollowed-out versions, mostly to reduce weight for clients, but we hadn't really attempted to "tune" it in the process. Clearly, weight was becoming an issue for some customers but we wanted to offer more as long as we were at it.
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Talladega first sketch
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The first version prototypes used various locations and sizes of chambers, but the thing that we kept running into was that when the chambers got big, the feedback got uncontrollable and unpredictable. What a surprise—any Jazz-box player could have foretold that. It was becoming clear that a series of smaller chambers was going to be the ticket, but just when we thought we'd got it right another problem surfaced. The Standard is a big instrument and it's relatively thin. The body is made from a single piece of mahogany and is already prone to warpage. On a smaller guitar you might not notice it, but over the wingspan of the Standard it was becoming a problem. The solution came from an unusual source.
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Improv top bracing
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Over the years we've been involved with developmental luthierie with our friends and partners in the acoustic world which includes the study of bracing patterns and top stiffness. Hundreds of deflection tests and dozens of brace pattern changes must have engraved themselves into my subconcious. What we came up with is an "X" brace pattern that maintains the stiffness of the instrument's body in all directions while yielding a weight loss of about 1.4 pounds on average. The series of small chambers of varying size reduces the tendency of any single resonance to get out of control at higher volumes, yet the response time to pick attack is noticeably heightened. It looks a little like fish bones.
In the end it worked so well, we've made it a "permanent" change. Well, as permanent as anything at Hamer is I guess. For the purists who want that original deep, heavy resonance of the original, we still offer that too.
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Standard chambering
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December 15, 2009
Inside the Cutaway |
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Today's peek into The Workshop reveals Dave at work on another blended neck joint—he's getting pretty good at this. Well, that's what we do here in the shop isn't it? This one take a special kind of touch however. It's a B-12A "acoustic" bass, and the inside of the cutaway exposes the side of the neck within the joint for a considerable amount of distance.
What Dave is doing here is feathering the blend with a piece of sandpaper rolled on a dowel. This gives him precise control of the amount and location of his sanding. The reason that's important is because as he sands the cutaway back he's actually exposing the neck along a line he creates with the sanding. His goal is to make the break point between body and neck a perfectly straight line. If you think it's as easy as it looks—well, it just aint! We'll come back to this build later to see the result.
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December 16, 2009
Twelve String Bass Build Continues |
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It's been a good day in The Workshop and as you can see from this photo Dave has done a great job of blending the neck joint on our B12A build. The feathered edge where the cutaway meets the maple of the neck has turned out really well with a nice straight edge.
It's touchy to build a neck with a full-width tenon on an instrument that has a deep cutaway like this as the body and its binding strip has to be feathered down to nothing at the point it "disappears" at the neck. Narrow tenon necks hide the joint under a shoulder, but don't get the advantage of the added vibration transfer of this kind of joint—that's why we like to do it.
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Let's just turn back the clock a few days because I want you to see the huge slab of mahogany that this bass was made from. Here, Dave and I are going over some details for another custom build that we have in the Workshop, and we're using the body blank of the B12A as a drafting table.
Older growth mahogany in sizes wide enough for a single piece bass or a Standard model are getting hard to come by. We've got a pretty good stash and are always accumulating more when we get a tip on some good stuff. We'll come back to this in a day or so to show you more so check back.
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December 17, 2009
Just Because...
Just because. I like this guitar, and looking at it makes me happy.
Just because - I can.
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December 19, 2009
Good Morning American Guitars |
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I like Saturday mornings even when it means rolling into work before the sun rises. The hard part, getting out of bed, is over and now the world is mine. Out here in rural New England there isn't a lot of traffic at this hour; and there's a special kind of solitude that descends on me as I negotiate the miles of curvy two-lane road that leads to The Workshop.
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Frost crunches underfoot as I walk to the door and take out my key. I can see just the slightest hint of daylight creeping over the roof of our 175 year-old mill building, the front of which is bathed in a freakish amber glow from the sodium lamp overhead.
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I glance at the clock and then hurry on my way, work-boots thumping across century-old maple floors, flipping circuit-breakers and pushing magnetic start buttons—firing up the tools of the trade before the crew arrives.
Today's main objective is to put a little milage on the custom orders that are in house. We like to take a week or so off around the holidays this time of year, so it's important to put the instruments into a sequence that takes advantage of the extra curing time.
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By the time I've made my rounds, Gary is already in the spray room tacking off the B12A that Dave has just completed. There are about seven instruments in various stages that need to be attended to, and Gary will begin with the ones that get the first nitro base coats. Then there will be some to color, and some that need topcoats.
As I write this, the light outside is chasing away the dark and I'm listening to the clank of the steam pipes and the creaking of the roof as the temperature changes. Most of the world is asleep at this hour, but we're making cool stuff. Yeah, it's too early for a weekend—and I love it.
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December 23, 2009
Just in Time For the Holidays |
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A while ago we collaborated with Seymour Duncan's user forum and raffled off a prize. We offered to do a complete set-up on a guitar—any guitar! Seymour threw in a pair of custom-wound pickups that would be tailored to the needs of the owner, and they were to be installed in our shop.
Then something special happened. The winner wanted to donate the prize to another forum member who was having some medical problems, and the love just starting pouring in. The consensus was so strong from fellow forumites that the deal was sealed, and arrangements were made.
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The new recipient of the set-up prize sent us his 2000 Gibson 335. That's right, we specified that we'd set up any guitar and that meant any brand—we're guitar lovers here, and that extends to all kinds. We don't usually do repair work, but restoration is where we came from so it was a bit like old times.
To be honest, when the guitar arrived it sounded great and played pretty well. I might have just left it as it was. It was loaded with Tom Holmes humbuckers which we've used before and they're top shelf. We'd discussed some of the issues and drawbacks of the guitars current configuration and Seymour came up with a plan. The pickups, based on the SLU neck and the Antiquity bridge were voiced to add tightness to the overall sound, and the decision to use Seymour's "Triple Shot" switching system surrounds would add a whole new world of tones to the guitar. When they arrived we noticed that they'd been engraved: "Lovebucker".
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Once we'd gotten the guitar apart, the first thing we did was have Dave go over the frets and take any grooving out. He re-crowned and polished the frets up nicely. That would take care of the slight buzzing that the owner had mentioned. After cleaning and oiling the fingerboard, Dave sent it over to the other end of the room to Todd.
The next step was for Todd to make a wiring loom that would fit into the guitar, and accommodate the Triple Shot switching. I gave him some pointers on how to do a 335, and suggested a teflon coated hookup coax with a braided shield covered in white insulation. It's a nice blend of old school and new tech. The bonus is twofold: it is a small diameter and very flexible which is good for a 335 and it is already insulated so we could do away with the messy shrink tubes that Gibson uses. The result would be very tidy and not as visible through the f-hole. We also put in a new switch.
The owner and I had discussed using oil filled caps, so I gave Todd some Angelas from my stash, with a value of .010 mfd. I figured that would add some nice honk if needed, seeing how the Triple Shots would give the option of twang. The Bridge pickup had alnico II magnets so I figured things would get interesting.
When Todd had things pretty well buttoned up, I did my final tweaking and found that the G string saddle needed to be turned around to get it to intonate properly. There are some disadvantages to the fret spacing on these guitars—I'd almost forgotten about how I re-calibrated our positions for modern strings, but all in all it intonated a lot better when we were done.
The results were quite apparent. The guitar fingered a bit better, and chords were more true up the neck. The tightness of the Lovebuckers was readily heard, making each note ring out in chords as opposed to being slurred. Pushing a Fender Tremolux a bit in the normal channel with the guitar's volume backed off slightly allowed single notes to sound round and full with a good bit of clarity that was missing before. When two or more notes were played, a nice bit of distortion could be coaxed to color the sound and give it edge. Popping the volume up on the guitar resulted in a nice lead tone without giving up to fluttery bottom. The pickups seemed to be doing exactly what Seymour had intended.
The Triple Shot surrounds were an interesting addition. Each bezel has two small slider switches that control the coils on the pickups. I was able to put either pickup into parallel or split coil configurations independently. Being a single-coil fan, this made the guitar come alive for me. The neck humbucker was fat and round—great for single note passages when distorted, but in the parallel mode, the chime really made me smile. The middle position with both pickups on became almost frustrating as there were so many options, all of them good, that it was hard to pick a favorite. I guess in a live or recording context, you'd know right away. Playing through my first generation Matchless DC30 really showed off what this setup could do, and I didn't want to stop.
All too soon it was time to pack up the guitar and get it out in time for Christmas, but it definitely left me thinking about a new guitar design to build. That's why I like all guitars, they open up doors to new rooms—or in this case old rooms with a new twist. Thanks to the Duncan team and the users forum (a great bunch of guitar fans) what a great story. To our winner—be well and enjoy, my friend!
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