Making "Ceol Binn Mór"

"Ceol Binn Mór"

 

I'm making "Ceol Binn Mór" an octave mandolin with a Lutz Spruce top and English Walnut back, sides and neck for Dave West.

 

Last updated 3/9/2018.

 

The main components are assembled.

Some "cunning plans".

Some initial glue ups to start with. The European Spruce top is initially thicknessed, jointed and glued up using hot hide glue and the tent method.

The English Walnut back is initially thicknessed, jointed and glued up using hot hide glue and the tent method.

The neck scarfe joint is cut and glued on the English Walnut neck blank using hot hide glue.

The stacked heel is glued up using hot hide glue.

The English Walnut sides are thicknessed. The soundport "porthole" is cut in the bass side using a 35mm Fostner bit.

Here's the result.

The Macassar Ebony centre of the "porthole" is cut and tested for fit.

The neck curves on the sides are bent by hand on the hot pipe and then the sides are bent in this jig. The sides are sprayed lightly with water, wrapped in brown paper and sandwiched as slat, side, slat, heating blanket, slat and the neck end clamped down to the bending form. The blanket is switched on and when hot enough the lower bout shape is bent.

After fine tuning on the hot pipe and some initial trimming here's the bent sides in the mould.

The Macassar Ebony porthole ring is glued to the Macassar Ebony backing plate using hot hide glue.

The centre of the porthole is then routed out.

Here's the result.

The Macassar "porthole" is then glued into the side using fish glue.

Next the Walnut neck block is made. This is a three piece construction and the first two pieces are glued together using hot hide glue.

The cap is glued on using fish glue.

The two 7mm bolt holes are then drilled.

The two 6mm holes are then drilled for the carbon fibre internal braces,

The slot for the fingerboard support is cut - the final depth of the slot will be determined when the neck is fitted.

The neck block is then initially shaped for the curvature of the sides.

The Lime tail block is made with two 6mm holes drilled for the internal carbon fibre braces. The 6mm carbon fibre tubes are then glued into the neck and tail blocks using. Next the neck-block is glued to the sides with fish glue using the mould as a jig.

The sides are glued to the tail block using fish glue.

The end graft channel is cut and the Macassar Ebony end graft flanked by black/ pear/ black purfling glued in using fish glue.

When the glue has dried the end graft is scraped flush - here’s the result.