Posted on March 3, 2024May 13, 2025 by Dale Phillips Mask for Belt Sanding Mask for Belt Sanding by John Calkin Published online by Guild of American Luthiers, March 2024 My 6×48 belt sander is my favorite and most used machines, though getting the most out of it didn’t come easy. It takes a knack to use one accurately, and that took years to develop. Perhaps most importantly, I learned to join plates and sculpt necks, saving myself scads of time over the years. This tip is about sanding parts on nearly completed instruments. It can be dangerous because the plates are already as thin as desired. In this case I needed to take down the end blocks of a dulcimer to the level of the plates. I had already shaped the sides of the blocks using a disk sander and sanding blocks. I used a scrap of poster board to mask the plates as I took down blocks to meet the plates. The end blocks weren’t that much oversize. A hand plane might have done this job as fast as my belt sander, But I never use handtools if a machine will do the job. Whew! I cut it close on this one, but it’s OK. The back of this dulcimer was already thinner than I liked. The block on the bridge end has to be larger to make room for some sort of string fixtures. There are also blocks inside the dulcimer to support the end blocks. The mask doesn’t have to be fancy or cover the entire plate. Sanding the block is done in quick steps with visual checking at every step. No sweat this time. All of the hand pressure on the sanding belt is applied to the block. I usually keep 80 grit belts on my sander. Sixty-grit would last longer and cut faster but the scratches require more work to remove. The abrasive barely touched the mahogany on this end. Most belt sanders of this size come with a 9" disk sander attached, but right from the factory mine wobbled badly. It was also frequently in the way, so I dismantled it. I considered returning the machine to Woodworker’s Supply, but repacking it would have been a lot of work. They still sell this machine. If they haven’t improved I wouldn’t buy it again. Standing the belt 90 degrees to the supplied work table turned out not to be a big deal, so I didn’t miss the disk sander very much. ◆
Posted on May 1, 2023March 23, 2026 by Dale Phillips Fall Collection 2024 Articles Online Fall Collection 2024 GAL Members – Login first before clicking on article titles to read the full articles. Not a member? You can join or renew here. Radiation from Lower Guitar Modes by Graham Caldersmith (1985) Caldersmith discusses the efficiency and pattern of sound radiation in the classic guitar produced by the four lower resonance modes, which he calls monopole, cross dipole, long dipole, and tripole. Inside Pacific Rim Tonewoods by Steve McMinn (1993) McMinn’s lutherie wood business has turned out to be a pretty big deal. Here we gain perspective by seeing it at the very beginning. The Great White Sitka by Jeffrey R. Elliott (1993) Holy Moby Spruce! How does one hack a log that’s eleven feet wide into 4000 guitar tops? Very carefully! By the way, this is a log that Steve McMinn rescued from the pulp mill. Meet the Maker: Bernard Millant by Jonathon Peterson (2006) Millant is a violin maker, a bow maker, an appraiser, an author, and a man of high repute within the violin world. The depth of training behind many old-school fiddle people will astonish most guitar makers, and it makes for entrancing reading. Meet the Maker: Dmitry Zhevlakov by Federico Sheppard (2007) This is not only the story of a Russian luthier who also makes beautiful rosettes for other builders, but is another example of how the Internet has changed the world — in this case for better. Aluminum Sonatas: A Brief History of Aluminum Stringed Instruments in the Last 120 Years by James Condino (2007) Every luthier knows how fickle and finicky the market is, so it’s no wonder that musical instruments made of aluminum didn’t catch on. Examined here are a violin, a mandolin, and a pair of bass viols. Fun stuff! Mechanical Compliance for Soundboard Optimization by David Hurd (2007) Hurd believes that the fastest way to great instruments is science, and it’s hard to argue with such a rational man. His jigs measure the deflection of top plates while under tension, and once he carves the top and braces to the numbers he wants, he’s done. This could be math heavy, but he offers an Internet spread sheet to ease the pain. Construction of the Colombian Tiple by Anamaria Paredes Garcia and R.M. Mottola (2007) Cross a 12-string flattop with a classical guitar and you get the Colombian tiple. The tiple has four courses of three steel strings, but on the inside, it’s a classical. Follow Alberto Paredes as he builds the instrument in this photo tour. See GAL Plan #51. Meet the Maker: Mervyn Davis by Rodney Stedall (2007) Davis’ South African upbringing inspires a wonderful decorative sense in his instruments. He’s built a ton of different stuff but may end up best known for his wildly unique modular guitars called Smooth Talkers. Cricket: A Reclaimed Salvage Recovery by James Condino (2007) Condino’s mandolin is made from recycled materials, mostly Douglas fir and katalox. It is unique and beautiful, and the story behind it is pretty cool, too. Grading on the Curves: Fitting Bars and Bridges on Archtop Guitars by Steve Andersen (2007) This is a very detailed look at how a notable builder of archtop guitars fits tone bars and bridges to his instruments. The Venezuelan Cuatro by Aquiles Torres (2008) Traditionally, this instrument is a small 4-string guitar with 14 frets clear, no frets over the body, a flush fretboard, and a large veneer tap plate. Note that the cuatro built for the article has 17 frets clear of the body. See GAL Plan #58. The MacRostie Mandolin Deflection Jig by Don MacRostie (2008) MacRostie’s clever jig measures the top deflection of a carved mandolin under string load at any stage of its construction. It is a valuable tool within the reach of any luthier. The “Corker” Guitar: A Sideport Experiment by Alan Carruth (2008) Carruth built a classical guitar with many small ports drilled in the side. By plugging the ports in various combinations he investigated the usefulness and physics behind them. Though this guitar did not make a believer out of him, he admits that his results are somewhat inconclusive. Electric Guitar Setup by Erick Coleman and Elliot John-Conry (2009) Two disciples of Dan Erlewine explain the latest techniques of setting up the electric guitar. All the details and specs are there, as well as a bit of philosophy. Dulcimer 101 by John Calkin (2009) Dulcimers are needlessly maligned and in need of advocates, and the author is a strong one. Tools and jiggery are kept to a minimum to make construction of this entry level instrument as accessible as possible. The Guitar as a Structure and Some Practical Information on Bracing by James Blilie (2009) A structural engineer and guitar builder sees the guitar as a thing buffeted by forces and stresses. Total Flame Out: Retopping a Harp Guitar by Harry Fleishman (2009) Harry replaces the failed soundboard on a complicated instrument with as little refinishing and other stress as possible. Strings: The (Often) Forgotten Accessory by Fan Tao (2010) D’Addario's resident scientist Fan Tao helps us understand string issues in relation to custom instruments and customized tuning. Practical Acoustics by Michael Cone (2010) Cone describes his advanced apparatus and method for acoustically testing classical guitars. Meet the Maker: James Ham by Roger Alan Skipper (2010) Ham operates from a shop in Victoria, B.C. where he repairs and restores violin family instruments and constructs world class double basses. It’s All About the Core or How to Estimate Compensation by Sjaak Elmendorp (2010) Mathematics and parameters used to address the problem of string compensation estimation. Articles Online Fall Collection 2024 Radiation from Lower Guitar Modes by Graham Caldersmith (1985) Caldersmith discusses the efficiency and pattern of sound radiation in the classic guitar produced by the four lower resonance modes, which he calls monopole, cross dipole, long dipole, and tripole. Inside Pacific Rim Tonewoods by Steve McMinn (1993) McMinn's lutherie wood business has turned out to be a pretty big deal. Here we gain perspective by seeing it at the very beginning. The Great White Sitka by Jeffrey R. Elliott (1993) Holy Moby Spruce! How does one hack a log that’s eleven feet wide into 4000 guitar tops? Very carefully! By the way, this is a log that Steve McMinn rescued from the pulp mill. Meet the Maker: Bernard Millant by Jonathon Peterson (2006) Millant is a violin maker, a bow maker, an appraiser, an author, and a man of high repute within the violin world. The depth of training behind many old-school fiddle people will astonish most guitar makers, and it makes for entrancing reading. Meet the Maker: Dmitry Zhevlakov by Federico Sheppard (2007) This is not only the story of a Russian luthier who also makes beautiful rosettes for other builders, but is another example of how the Internet has changed the world — in this case for better. Aluminum Sonatas: A Brief History of Aluminum Stringed Instruments in the Last 120 Years by James Condino (2007) Every luthier knows how fickle and finicky the market is, so it’s no wonder that musical instruments made of aluminum didn’t catch on. Examined here are a violin, a mandolin, and a pair of bass viols. Fun stuff! Mechanical Compliance for Soundboard Optimization by David Hurd (2007) Hurd believes that the fastest way to great instruments is science, and it’s hard to argue with such a rational man. His jigs measure the deflection of top plates while under tension, and once he carves the top and braces to the numbers he wants, he’s done. This could be math heavy, but he offers an Internet spread sheet to ease the pain. Construction of the Colombian Tiple by Anamaria Paredes Garcia and R.M. Mottola (2007) Cross a 12-string flattop with a classical guitar and you get the Colombian tiple. The tiple has four courses of three steel strings, but on the inside, it’s a classical. Follow Alberto Paredes as he builds the instrument in this photo tour. See GAL Plan #51. Meet the Maker: Mervyn Davis by Rodney Stedall (2007) Davis’ South African upbringing inspires a wonderful decorative sense in his instruments. He’s built a ton of different stuff but may end up best known for his wildly unique modular guitars called Smooth Talkers. Cricket: A Reclaimed Salvage Recovery by James Condino (2007) Condino’s mandolin is made from recycled materials, mostly Douglas fir and katalox. It is unique and beautiful, and the story behind it is pretty cool, too. Grading on the Curves: Fitting Bars and Bridges on Archtop Guitars by Steve Andersen (2007) This is a very detailed look at how a notable builder of archtop guitars fits tone bars and bridges to his instruments. The Venezuelan Cuatro by Aquiles Torres (2008) Traditionally, this instrument is a small 4-string guitar with 14 frets clear, no frets over the body, a flush fretboard, and a large veneer tap plate. Note that the cuatro built for the article has 17 frets clear of the body. See GAL Plan #58. The MacRostie Mandolin Deflection Jig by Don MacRostie (2008) MacRostie’s clever jig measures the top deflection of a carved mandolin under string load at any stage of its construction. It is a valuable tool within the reach of any luthier. The “Corker” Guitar: A Sideport Experiment by Alan Carruth (2008) Carruth built a classical guitar with many small ports drilled in the side. By plugging the ports in various combinations he investigated the usefulness and physics behind them. Though this guitar did not make a believer out of him, he admits that his results are somewhat inconclusive. Electric Guitar Setup by Erick Coleman and Elliot John-Conry (2009) Two disciples of Dan Erlewine explain the latest techniques of setting up the electric guitar. All the details and specs are there, as well as a bit of philosophy. Dulcimer 101 by John Calkin (2009) Dulcimers are needlessly maligned and in need of advocates, and the author is a strong one. Tools and jiggery are kept to a minimum to make construction of this entry level instrument as accessible as possible. The Guitar as a Structure and Some Practical Information on Bracing by James Blilie (2009) A structural engineer and guitar builder sees the guitar as a thing buffeted by forces and stresses. Total Flame Out: Retopping a Harp Guitar by Harry Fleishman (2009) Harry replaces the failed soundboard on a complicated instrument with as little refinishing and other stress as possible. Strings: The (Often) Forgotten Accessory by Fan Tao (2010) D'Addario's resident scientist Fan Tao helps us understand string issues in relation to custom instruments and customized tuning. Practical Acoustics by Michael Cone (2010) Cone describes his advanced apparatus and method for acoustically testing classical guitars. Meet the Maker: James Ham by Roger Alan Skipper (2010) Ham operates from a shop in Victoria, B.C. where he repairs and restores violin family instruments and constructs world class double basses. It’s All About the Core or How to Estimate Compensation by Sjaak Elmendorp (2010) Mathematics and parameters used to address the problem of string compensation estimation.
Posted on April 21, 2023May 14, 2025 by Dale Phillips Meet the Maker: Henry Stocek Meet the Maker: Henry Stocek by John Calkin Originally published in American Lutherie #62, 2000 and Big Red Book of American Lutherie Volume Six, 2013 There is a host of nonluthiers without whom lutherie would suffer. I refer to the makers and suppliers of the products that eventually comprise our instruments — the wood, trim items, pickups, cases, hardware, and finish products that make instruments more functional and more interesting. It should come as no surprise that most of these folks are as fascinating and dedicated as any luthier. We’ve met a few of them in these pages before, and I hope to give more of them the exposure they deserve. First up is Henry Stocek, the celluloid guru who introduced us to the art of turtleoid creation (see Reinventing the Celluloid Tortoise). He created Deep River Vintage Instrument Supply to furnish the trade with imitation tortoiseshell pickguard stock that was reminiscent of the color and patterns used in the ’30s. Other items are on the way. Become A Member to Continue Reading This Article This article is part of our premium web content offered to Guild members. To view this and other web articles, join the Guild of American Luthiers. Members also receive 4 annual issues of American Lutherie and get discounts on products. For details, visit the membership page. If you are already a member, login for access or contact us to setup your account.
Posted on November 1, 2022May 21, 2025 by Dale Phillips Little Dobro Little Dobro by John Calkin Published online by Guild of American Luthiers, November 2022 I bet that a lot of instrument makers don't know what their hourly wage is. I came with this idea for a resonator guitar with the idea of making a specific wage. The body, including the perforated ring that supports the resonator cone, was made of construction-grade plywood. The neck and fingerboard stock was sourced locally in bulk. The body hardware came from StewMac and the machines from Schaller. The textured paint required no work after it was sprayed from the can, though the necks were lacquered normally. The rosette was made of shark teeth that I got from my friend Cousin Al (who wasn't my cousin at all.) It was not difficult to price all the materials accurately. I timed myself as I made the first two of these guitars. I wanted to make $15 per hour, which was a good wage back then, and I probably made a little more after some practice. I sold them for $600 with no case. Everything was very business-like. Sometimes we forget that lutherie is a business and get lost in it without making enough money. ◆ All photos by John Calkin
Posted on July 8, 2022May 22, 2025 by Dale Phillips Quickie Sander Fence Quickie Sander Fence by John Calkin Published online by Guild of American Luthiers, July 2022 Every lutherie shop has jigs hanging around. Often, lots of them. Every sort of stringed instrument is easier and faster to build using good jigs. If you decide that you'd like to build all of the instrument types commonly played in America you will accumulate a serious number of jigs. These days just about all of the most useful jigs can be purchased from a variety of dealers. They are very pretty and often better-made and more useful than a jig we would bother to make in our own shop. Well, prettier, anyhow. If you have entered lutherie in the last fifteen years you may have grown tired of old-timers complaining about this, as if making all of your own jigs was a right of passage that should never be skipped. "In my day we couldn't buy a guitar jig of any kind anywhere! We were lucky to find a book with pictures of guitars, let alone instructions to make them. Huff!" Well, sometimes we need a jig or fixture (what's the difference, anyhow?) that isn't instrument-specific, but machine-specific. I have vague memories of making a right-angle fence for my 6×48 belt sander. I still have the same sander, so when I rediscovered the jig---er, fixture---a few weeks ago I was glad to see it. But as soon as I turned my back, darn if it didn't go into hiding again. I have bumped around my little shop a number of times searching for it but to no avail. So, today I made a new one. I remember having to shim the old one to get it square. The new one came out dead on the money. I'll claim that forty years of experience was responsible for that, rather than blind luck. Old-farts in the game are entitled to that. Belt sanders vary enough in design that I won't bother listing any dimensions. I have included enough photos to suggest the jist of it. Anyway, you'll probably want the fence to be longer, or taller, or shaped like an animal for all I know. I sat it on a thin spacer to clear the belt, and it remained there nicely while I put on the clamps. Use the smallest clamps that will work in order not to bump them against the underside edge of the belt. Good luck. ◆ All photos by John Calkin.
