Another day with the 180 grit sandpaper. Although I did put together another sanding block for the waists, narrow with two thickness's of cork and I even rounded the cork edges to make sure I got well into the radius to sand.

I started on Ruth's neck and headstock and got them into the same condition as the body. And then I went back to my uke and started sanding in more detail. I was using the small sanding block to make sure I didn't 'ride over' areas that needed attention.

Basically, at this stage I am looking to remove all tool marks and blemishes. No scratches, no pressure marks from the binding cutting tool, no stray pressure marks from a finger nail. Just get the wood surface as flat and smooth as possible. Any marks in the surface of the wood will remain visible once the finish is applied. So once I sanded the guitar all over, I wiped over again with white spirits to lift the dust and to highlight the last remaining marks. And I worked every inch of the uke. This is how it looks so far.





It will need at least another full sanding to make sure there are no flaws, and with special attention to the neck, heel, and volute. But it is very close. I'll be doing the same again tomorrow with the other uke.

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Just to let you know my man in Ireland let me know my Bouzola/Mandouki will be ready early January!

Started in September/October so I doubt it will be as painstakingly put together as this pair, Andy - loving the thread.

--------------------
Me? But I`m such a loveable old bugger!

Thanks Ivan

I'm sure it will be put together at least as well. 3-4 months sounds about right, I'm a lot slower because I'm building two at the same time, I'm only working 2 to 4 hours each afternoon, and I'm not using a fully equipped workshop; just simple tools on a basic bench.

Off sanding again in a couple of hours

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Back from sanding...

actually, I was back from sanding hours ago. I've eaten, done some odds 'n' sods, been to the pub, and not long got back.

Had a pleasant afternoon making sawdust and sanding Ruth's uke. Went all over and it's looking good. Need to double check, but it looks like the only marks remaining are the sanding marks from the 180 grit paper. If so, next step is to start on the finer grades on both.





Yes, I know the pics are getting boring now, but I did warn you. But new pics prove that I was doing something !!

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Boring? Says who?

I'm not finding them at all boring

--------------------
It wasn't me!
(Well, actually, it probably was)

Not a successful day at Ukulele Central today. I thought I'd move up from the 180 grit sandpaper to some 400 grit wet & dry. But it wasn't a very god idea. The paper clogged badly and left some nasty scuffs in the front of my uke. So it was out with the 180 grit again to tidy up.

And I'm off to get some more suitable fine grade papers next week.

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Still trying to find decent sandpaper locally. If all else fails I'll order online, but that means no more work until the New Year..

Andy

--------------------
When the going gets weird, the Weird turn Pro.

I guess that means you'll have to spend the next week or so eating and drinking to take you mind of things

--------------------
It wasn't me!
(Well, actually, it probably was)

If I remember correctly this doesn't clog, in fact nothing sticks to it at all



--------------------
Madman_Greg

Quote Madman_Greg:

---

If I remember correctly this doesn't clog, in fact nothing sticks to it at all

---

But it only comes in 80 grit

Andy

--------------------
When the going gets weird, the Weird turn Pro.

I know what you could be doing Andy, between now and the new year. There is a special lubricant just for luthiers which could usefully be applied. And it was a vintage year for the special apples they use to make it

--------------------
Strictly project and just for fun

Good plan... Sanatogen it is

Andy

--------------------
When the going gets weird, the Weird turn Pro.

finally managed to pick up some decent fine sandpaper, so we'll get New Year out of the way and get back to work

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Ahem...

--------------------
It wasn't me!
(Well, actually, it probably was)

By getting the New Year out of the way... I meant the WHOLE of 2012.

Back in 2013 for more thrilling instalments involving sandpaper and sawdust.














Just kidding, back next week

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Hey - what's happened to these Uke's - I need a Uke update soon please

--------------------
Mac Pro, Logic Pro, lots of software and 17 hard drives!

Sorry Jonny...

As you can see from the pics, the workshop is just a garage with the door open. I've been a little unwell recently, nothing serious, but need to keep inside and warm. But I should be back in a day or two with real progress. I'm almost completely well now

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Hiya Andy,

Thanks for the update - get well soon - your posts are a fascinating insight into a world I know little about but have huge admiration for.

Keep up the good work!


JP

--------------------
Mac Pro, Logic Pro, lots of software and 17 hard drives!

Quote zenguitar:

---

Sorry Jonny...

As you can see from the pics, the workshop is just a garage with the door open. I've been a little unwell recently, nothing serious, but need to keep inside and warm. But I should be back in a day or two with real progress. I'm almost completely well now

Andy

---

Hmmm. Maybe time to get an apprentice!

Get well soon mate.

--------------------
It wasn't me!
(Well, actually, it probably was)

You all right Mr?!

--------------------
Mac Pro, Logic Pro, lots of software and 17 hard drives!

I'm back to full health, just keeping an eye on the weather and itching to get everything finished

I really am working in a garage with the door open to the elements. I'm pretty tough, but it does help to be able to feel your fingers when working

Back to work soon, I promise.

Andy

--------------------
When the going gets weird, the Weird turn Pro.

I have just found this incredible topic & have spent the last hour or two reading, & watching the progression of the two Ukes, & am thrilled & amazed by the workmanship, grace & laughter to be had. I could feel the microscopic eyeballs turning on, as you described the "boring" last phase - totally fascinating if you ask me!

I hope that all is well & that you can finish off the project, Mr Zenguitar Andy; for yourself, for Ruth & for the rest of us looking in. It's almost like being there, but I miss the smell of the wood.

cheers,
Luke

Edited by Lanman (15/04/12 02:25 PM)

Nice one Luke. We are all waiting with excited anticipation. The man has told us he will take the final stroll to the summit, no doubt with seemingly effortless flair and panache, when he judges the moment to be right (and his temporary workshop/bones have thawed out enough after a bitter winter). As musicians we do not interrupt between another musicians notes. And we do not interrupt a craftsman at his work, lest we find ourselves at the wrong end of a flying mallet! But I'm looking forwards to the finale just as much.

(Note: Sub zero temperatures expected in parts of the UK again this week...)

--------------------
Strictly project and just for fun

Ah, well, I've been sulking for a week or so....

remember how the back of Ruth's Uke split and we never got to the bottom of why it happened?

Well, I have a much clearer idea now. It wasn't the changes in humidity or temperature, at least not directly, it was a flaw in the wood. And how, you may ask, do I know that now?

Well, the damn thing did the same again

The full length split from before has reappeared but on the opposite half of the back and the other major split has also reappeared on the other half. The good news is that the previous repairs are rock solid.

Now, the clue is that it's a beautiful piece of wood. The thing that makes it look so good is how wild the grain is, and in turn, that was the cause of the weaknesses that led to the splits. I am now struggling to decide between three options.

One, there is an outside chance that I could repair the two splits without taking the back off. It all depends on how accurately and tightly I can clamp the back, but it is high risk because if it doesn't work first time I will have to make a new back and fit it. Expensive, time consuming, and frustrating because it is a beautiful piece of wood.

Two, do the same repair as I did before. Less expensive, although I still need to get replacement bindings from the USA, but takes a lot of work. It preserves the lovely wood though. It is 99% certain that a repair would be as good as the previous one, but a risk that another winter might see it off.

Three, cut my losses and go straight to sourcing a replacement Pheasant Wood back, bindings, and replacing it.

I wouldn't have minded so much if it had been my uke suffering. I would have just got on with finishing Ruth's and sorted mine out later, or even just put it down to experience and moved on to the next one.

Oh well, I have to make a decision eventually...

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Bummer + many. So sorry to hear that Andy. That's three hard choices. As Harold Wilson would have said, a two pipe dilemma...

I don't suppose it will make you feel any better but for what it's worth I managed to put a split in my Martin over the winter. And it was a heat and humidity issue (that I should have seen developing, stupid of me). My good news was that the right glue in the hands of a trusted luthier has made a perfect mend and she plays beautifully again. Mind you, your reticence about options one and two are getting me worried that it might happen again next year! They both seem tempting for you though, and its not as if you don't have option three to fall back on.

I'll have a couple of pipes in solidarity. All the best

--------------------
Strictly project and just for fun

Absolutely gutted to hear this. Things had been going along so well and it looked like the first split was just a one-off aberration. I admire your patience.

I'm afraid I'm rather reminded of an Einstein quote which went something like:

I do not accept two. A singularity yes, but if an event can take place twice there is no limit to how many times it can do so.

--------------------
It wasn't me!
(Well, actually, it probably was)

Genuinely gutted to hear it, after all the work you've put in so far.

Face it, you're never going to be confident about option two, so why not try option one? That way the worst thing that can happen is that you end up with option three.

I appreciate that's easily said when you're not actually the one doing all the work.

DM

--------------------
Not much in life worth running for. Or from.

In a word - arse!

Quote grab:

---

In a word - arse!

---

My thoughts exactly. It's such a pity to hear this.

Dan

HEY!!!

Project Ukulele is GO!! Again

Having vegetated, cogitated, anticipated, and on occasion constipated... I'm now satisfied about the possible causes and potential outcomes and have reached a decision.

My initial observations were wrong, it wasn't the wood splitting on the other side of the back (note to self, don't rely on memory and get used to early onset dementia...), it was two of the previous repairs re-opening. The cause was having to glue 6 splits and then clamp all in one go. The glue was already going off before I got it all clamped.

So, these splits WILL be fixed (whether they like it or not) and work is starting again. Replacement bindings and purflings have been ordered from LMI, and delivered. I've spent the last two afternoons preparing the workbench, cleaning up, and sharpening the tools of the trade. And tomorrow I start work on removing the back again !!

Abnormal Service HAS been resumed

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Welcome back Zen - my life is now complete once more :-)

--------------------
Mac Pro, Logic Pro, lots of software and 17 hard drives!

Quote zenguitar:

---

(note to self, don't rely on memory and get used to early onset dementia...)

---

Its not the onset of premature dementia, Andy. I understand you celebrate a significant birthday next year. You are therefore allowed to quite properly refer to these things as a 'senior moment'. Best avoided by not rushing at anything! I had wondered when you'd get fed up with waiting for the weather to improve.

This is great news, resulting in (at least one) brief moment of rapture in London. Eagerly anticipating the next dispatch.

Francis.

--------------------
Strictly project and just for fun

Absolutely delighted to see you're back in the 'grove' (for want of a better term). So I'll have an extra glass of wine with my dinner in celebration

--------------------
It wasn't me!
(Well, actually, it probably was)

Many thanks Guys

Hmmm... yes... Senior Moment... NAH!!! I'm still young And that significant birthday is at the end of the month, Hawaii Five O

But with the tools sharpened and the bench cleared, I had no excuses. So into the vice went the offending Uke, and out came the razor saw and Dremel to attack the back bindings once more.

The camera batteries were flat, so while they were on charge I grabbed a pic with the mobile phone. I know you like pics.



And after cutting through the binding to the purflings I grabbed a freshly sharpened chisel and started cutting back to reveal the back and kerfings inside. And I only slipped once, no major damage, nothing a plaster couldn't fix

And tomorrow, a little bit of final trimming back and then I can get out the hot knife and remove the back again

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Well, this evening I took the plaster off my finger and the cut hasn't re-opened. I know that's not of any great interest to anyone else, but it makes a difference to me

What you all want to see is this...








Everything ready to remove that pesky back. The bowl of water isn't needed to take the back off, but it's there because the bending iron I use to heat the knife gets very hot. If I am foolish enough to get burned (and it will make a nasty burn quickly), I like to have some cold water close by to minimise the damage.

Then it's just a matter of heating the knife and easing it between the back and the kerfings like this.



I use an old dinner knife, but a palette knife will do just as well or better. You want to avoid using something so sharp that it cuts the wood, what you need is something thin enough to work into the glue joint and let the heat do the work of breaking it.



And after carefully working all around the back edge, it's just held on by the braces. I did quite a good job of breaking the glue join between the back and braces too, but rather than force it and do damage I got out the razor saw again and cut the braces. I'm going to have to lose them and make new ones again anyway.



And here it is with the back removed. NOTE TO SELF... there must be better ways of removing cobwebs from inside an instrument

Andy

--------------------
When the going gets weird, the Weird turn Pro.

Slicing and dicing digits. Incinerating other digits. Infestations of arachnids! Its a long, hard road is this Ukulele building. Good to see the project well and truly back on track, even if it is one step back for two steps forward. Hopefully by this time next week you'll be back in the black Andy.

--------------------
Strictly project and just for fun

Indeed, 'tis all going quicker this time.

Here I am removing the remnants of the braces.



And once I've finessed them out, this is what's left.



Then time for a quick clean up of the body. Not finished yet, but at least the cobwebs are gone !!



Day off tomorrow and sunday. Then next week I will get some fresh glue, and work out how to clamp the back for glueing. As there are two pieces to be glued I intend to do it in at least two stages (there might be some minor splits that need attention after the stresses of dismantling).

Andy

--------------------
When the going gets weird, the Weird turn Pro.

So, back in the workshop today. And getting ready to start glueuing the back again!!



Yeah, I know, not the most exciting pic of all time. But I know you are all keeping tabs on me and need evidence that I've been doing some work.

I've re-glued the loose strip of cork on the clamping caul. I've knocked up a caul to sit over the glue join and keep things level. There's a piece of scrap to hold the centre section in place.

Off running errands tomorrow, and while I'm out I'll be shopping. Mainly for food, but I'll get some nice, fresh, glue and I might even get the first piece glued on by this time tomorrow.

Andy

--------------------
When the going gets weird, the Weird turn Pro.

I managed to wake up in time to do my chores around the house, then go shopping. Got a small (and grossly overpriced, I might add) thingy of fresh glue. Some food too. Then home in time to get down to some luthiery as normal.

After a little preparation, it looked like this.



The back securely clamped to the baseboard. Some well waxed paper in place under the edge to be glued. More well waxed paper to go under the clamping caul I knocked up. Loops of string in place. And more clamps ready. And after recently giving advice that you shouldn't buy glue in too large quantities because it goes off, I followed my own advice and bought a small size. The big bottle I was using was probably past it's use by date before we even started this project. So I'll admit to learning the hard way. One of the probably causes for the splits re-opening was the glue under-performing, so large bottles of glue are definitely a false economy. And even this small bottle has more than enough glue to have completed both ukes.

Anyway, after that it was time to bite the bullet and apply some of that lovely new glue and clamp things up nice and tight.



I had a couple of attached splinters, so I made a point of easing a little glue into those too. Then it was time to clamp up. After lining up the broken off section I applied gentle pressure with a single clamp to the caul, just to keep things flat and flush (I want to minimise the amount of wood I need to remove from the back to make if flat again after), I tightened up the loops of strings Spanish Windlass style once more. And when things were good and tight, I clamped the caul down hard with two clamps.

Fingers crossed.

Once you do it, you have you wait and see how it turns out, and trust to your skills and technique. Tomorrow, I remove it from the clamps, and start working on the other split.

Andy


--------------------
When the going gets weird, the Weird turn Pro.

Fingers crossed

--------------------
It wasn't me!
(Well, actually, it probably was)